Indium gallium nitride red light emitting diode and method of making thereof

ABSTRACT

A red-light emitting diode includes an n-doped portion, a p-doped portion, and a light emitting region located between the n-doped portion and a p-doped portion. The light emitting region includes a light-emitting indium gallium nitride layer emitting light at a peak wavelength between 600 and 750 nm under electrical bias thereacross, an aluminum gallium nitride layer located on the light-emitting indium gallium nitride layer. and a GaN barrier layer located on the aluminum gallium nitride layer.

FIELD

The embodiments of the invention are directed generally to semiconductorlight emitting devices, and specifically to a red-light emitting diodeincluding indium gallium nitride, and a method of manufacturing thesame.

BACKGROUND

Light emitting devices such as light emitting devices are used inelectronic displays, such as liquid crystal displays in laptops or LEDtelevisions. Light emitting devices include light emitting diodes (LEDs)and various other types of electronic devices configured to emit light.

SUMMARY

According to an aspect of the present disclosure, a red-light emittingdiode comprises an n-doped portion, a p-doped portion and a lightemitting region located between the n-doped portion and a p-dopedportion. The light emitting region comprises a light-emitting indiumgallium nitride layer emitting light at a peak wavelength between 600and 750 nm under electrical bias thereacross, a III-nitride layerlocated on the light-emitting indium gallium nitride layer; and a GaNbarrier layer located on the III-nitride layer. The light emitting diodecomprises at least one feature selected from: (a) the light emittingdiode comprises a nanowire device; or (b) the light emitting regionconsists of one or two quantum wells; or (c) the III-nitride layercomprises an aluminum gallium nitride layer which has a compositionAl_(y)Ga_((1-y))N, where y is in a range from 0.3 to 1.0; or (d) UVemitting InGaN/GaN superlattice is located between the n-doped portionand the light emitting region.

According to another aspect of the present disclosure, a nanowirered-light emitting diode includes an n-doped nanowire core portion, ap-doped portion; and a light emitting shell located on the n-dopednanowire core under the p-doped portion. The light emitting shellcomprises a light-emitting indium gallium nitride shell emitting lightat a peak wavelength between 600 and 750 nm under electrical biasthereacross, a III-nitride shell located on the light-emitting indiumgallium nitride shell, and a GaN barrier shell located on theIII-nitride shell.

According to another aspect of the present disclosure, a method ofmanufacturing a direct view display device includes providing firstlight emitting diodes, wherein each of the first light emitting diodescomprises an epitaxial material layer stack configured to emit light ata first peak wavelength in a range from 600 nm to 750 nm, wherein theepitaxial material layer stack comprises, from one side to another, asingle crystalline n-doped GaN portion, a plurality of strain-modulatinglayer stacks located on the single crystalline n-doped GaN layer andcomprising a respective intervening indium gallium nitride layer and arespective intervening GaN layer, a light-emitting indium galliumnitride layer located on the plurality of strain-modulating layer stacksand emitting light at the first peak wavelength under electrical biasthereacross, a GaN barrier layer, and a p-doped aluminum gallium nitridelayer. The method also includes providing second light emitting diodesconfigured to emit light at a second peak wavelength in a range from 400nm to 600 nm, and bonding the first light emitting diodes and the secondlight emitting diodes to a backplane to form an array of pixels.

According to another aspect of the present disclosure, a direct viewdisplay device comprising an array of pixels located on a backplane isprovided. Each of the pixels comprises a first light emitting diodeconfigured to emit light at a first peak wavelength in a range from 600nm to 750 nm, and a second light emitting diode configured to emit lightat a second peak wavelength in a range from 400 nm to 600 nm. The firstlight emitting diode in each pixel includes an epitaxial material layerstack comprising, from one side to another: a single crystalline n-dopedGaN portion; a plurality of strain-modulating layer stacks located onthe single crystalline n-doped GaN layer and comprising a respectiveintervening indium gallium nitride layer and a respective interveningGaN layer; a light-emitting indium gallium nitride layer located on theplurality of strain-modulating layer stacks and emitting light at thefirst peak wavelength under electrical bias thereacross; a GaN barrierlayer; and a p-doped aluminum gallium nitride layer.

According to another aspect of the present disclosure, a method ofmanufacturing a direct view display device is provided, which comprisesthe steps of: providing first light emitting diodes, wherein each of thefirst light emitting diodes comprises an epitaxial material layer stackconfigured to emit light at a first peak wavelength in a range from 600nm to 750 nm, wherein the epitaxial material layer stack comprises, fromone side to another: a single crystalline n-doped GaN portion, aplurality of strain-modulating layer stacks located on the singlecrystalline n-doped GaN layer and comprising a respective interveningindium gallium nitride layer and a respective intervening GaN layer, alight-emitting indium gallium nitride layer located on the plurality ofstrain-modulating layer stacks and emitting light at the first peakwavelength under electrical bias thereacross, a GaN barrier layer, and ap-doped aluminum gallium nitride layer; providing second light emittingdiodes configured to emit light at a second peak wavelength in a rangefrom 400 nm to 600 nm; and bonding the first light emitting diodes andthe second light emitting diodes to a backplane to form an array ofpixels.

According to an aspect of the present disclosure, a direct view displaydevice comprising an array of pixels located on a backplane is provided.Each of the pixels comprises a red-light emitting diode configured toemit light at a peak wavelength in a range from 620 nm to 750 nm, agreen-light emitting diode configured to emit light at a peak wavelengthin a range from 495 nm to 570 nm, and a blue-light emitting diodeconfigured to emit light at a peak wavelength in a range from 450 to 495nm. The red-light emitting diode in each pixel comprises: a first singlecrystalline n-doped gallium nitride layer; a single crystalline n-dopedindium gallium nitride layer in epitaxial alignment with the singlecrystalline n-doped gallium nitride layer; an active layer including atleast one instance of an indium gallium nitride layer and at least oneinstance of a compound semiconductor material layer having a greaterband gap than the at least one indium gallium nitride layer; and a firstp-doped compound semiconductor material layer, wherein the active layeris configured to emit light at a peak wavelength in a range from 620 nmto 750 nm upon application of electrical bias between the singlecrystalline n-doped indium gallium nitride layer and the p-dopedcompound semiconductor material layer.

According to another aspect of the present disclosure, a method ofmanufacturing a direct view display device is provided. Red-lightemitting diodes are provided, wherein each of the red-light emittingdiode comprises: a first single crystalline n-doped gallium nitridelayer; a single crystalline n-doped indium gallium nitride layer inepitaxial alignment with the single crystalline n-doped gallium nitridelayer; an active layer including at least one instance of an indiumgallium nitride layer and at least one instance of a compoundsemiconductor material layer having a greater band gap than the at leastone indium gallium nitride layer; and a first p-doped compoundsemiconductor material layer, wherein the active layer is configured toemit light at a peak wavelength in a range from 620 nm to 750 nm uponapplication of electrical bias between the single crystalline n-dopedindium gallium nitride layer and the p-doped compound semiconductormaterial layer. The methods includes the steps of: providing green-lightemitting diodes configured to emit light at a peak wavelength in a rangefrom 495 nm to 570 nm; providing blue-light emitting diodes configuredto emit light at a peak wavelength in a range from 450 to 495 nm; andbonding the red-light emitting diodes, the green-light emitting diodes,and the blue-light emitting diodes to a backplane to form an array ofpixels.

According to another aspect of the present disclosure, a method offorming a device assembly is provided. Multiple types of solder materialportions are formed on a substrate. The multiple types of soldermaterial portions comprises at least one first solder material portionincluding a first solder material and at least one second soldermaterial portion including a second solder material. Multiple types ofdevices are provided. The multiple types of devices comprises a firsttype device including at least one first bonding pad and a second typedevice including at least one second bonding pad. The first and secondbonding pads comprise a common bonding material. The first soldermaterial and the common bonding material form a first eutectic systemhaving a first eutectic temperature. The second solder material and thecommon bonding material form a second eutectic system having a secondeutectic temperature that is greater than the first eutectictemperature. The first type device is bonded to the substrate bydisposing each first bonding pad on a respective first solder materialportion and heating each first bonding pad to a temperature above thefirst eutectic temperature and below the second eutectic temperature.The second type device is bonded to the substrate by disposing eachsecond bonding pad on a respective second solder material portion andheating each second bonding pad to a temperature above the secondeutectic temperature.

According to an aspect of the present disclosure, a method of forming atleast one integrated light emitting device assembly is provided. A firstassembly comprising a first source substrate and first light emittingdevices that emit light of a first wavelength is disposed over abackplane. First conductive bonding structures are disposed between thebackplane and the first assembly. A first subset of the first lightemitting devices is bonded to the backplane through the first conductivebonding structures. The first subset of the first light emitting devicesis detached from the first source substrate by laser ablation ofmaterial portions overlying the first subset of the first light emittingdevices. An assembly comprising the first source substrate and a secondsubset of the first light emitting devices is separated from thebackplane while the first subset of the first light emitting devicesremains bonded to the backplane.

According to another aspect of the present disclosure, an integratedlight emitting device assembly is provided, which comprises a backplanehaving stepped horizontal surfaces at a top side. The stepped horizontalsurfaces comprise a first subset of the stepped horizontal surfaceslocated within a first horizontal surface plane, and a second subset ofthe stepped horizontal surfaces located within a second horizontalsurface plane that is more proximal to a backside surface of thebackplane than the first subset of stepped horizontal surfaces is to thebackside surface of the backplane. The integrated light emitting deviceassembly comprises conductive bonding structures located on the steppedhorizontal surfaces of the backplane. The conductive bonding structurescomprise first conductive bonding structures overlying the first subsetof the stepped horizontal surfaces and second conductive bondingstructures overlying the second subset of the stepped horizontalsurfaces. Further, the integrated light emitting device assemblycomprises light emitting devices bonded to the conductive bondingstructures. The light emitting devices comprise first light emittingdevices that emit light of a first wavelength and overlie the firstsubset of the stepped horizontal surfaces and second light emittingdevices that emit light of a second wavelength and overlie the secondsubset of stepped horizontal surfaces.

According to yet another aspect of the present disclosure, an integratedlight emitting device assembly comprising first light emitting devicesand second light emitting devices bonded to a backplane is provided.Each first light emitting device emits light at a first wavelength. Eachsecond light emitting device emits light at a second wavelength that isdifferent from the first wavelength. Each first light emitting device isbonded to the backplane through a first stack including a first bondingpad and a first conductive bonding structure. Each second light emittingdevice is bonded to the backplane through a second stack including asecond bonding pad and a second conductive bonding structure. A firstplane including first interfaces between the first bonding pads and thefirst conductive bonding structures is vertically offset from a secondplane including second interfaces between the second bonding pads andthe second conductive bonding structures.

According to still another aspect of the present disclosure, anintegrated light emitting device assembly comprising first lightemitting devices and second light emitting devices bonded to a backplaneis provided. Each first light emitting device emits light at a firstwavelength. Each second light emitting device emits light at a secondwavelength that is different from the first wavelength. Each first lightemitting device is bonded to the backplane through a first stackincluding a first bonding pad and a first conductive bonding structure.Each second light emitting device is bonded to the backplane through asecond stack including a second bonding pad and a second conductivebonding structure. The first conductive bonding structures and thesecond conductive bonding structures have a same height. Each of thefirst conductive bonding structures has a first volume. Each of thesecond conductive bonding structures has a second volume that is lessthan the first volume.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of the step of generation ofassemblies of growth substrates with respective devices thereupon frominitial growth substrates according to an embodiment of the presentdisclosure.

FIG. 2 is a schematic illustration of the step of bonding of the growthsubstrates to respective first carrier substrates through the respectivedevices according to an embodiment of the present disclosure.

FIG. 3 is a schematic illustration of the step of removing the growthsubstrates according to an embodiment of the present disclosure.

FIG. 4 is a schematic illustration of the step of forming a firstbonding material layer on the first carrier substrates, providing secondcarrier substrate, and forming a release layer and a second bondingmaterial layer according to an embodiment of the present disclosure.

FIG. 5 is a schematic illustration of the step of bonding each pair of afirst carrier substrate and a second carrier substrate according to anembodiment of the present disclosure.

FIG. 6 is a schematic illustration of the step in which each firstcarrier substrate is removed from a bonded structure according to anembodiment of the present disclosure.

FIG. 7 is a vertical cross-sectional view of a second carrier substrate,an array of first light emitting devices thereupon, and an optionaloptical protection material layer that fills gaps among the first lightemitting devices according to an embodiment of the present disclosure.

FIG. 8 is a vertical cross-sectional view of a backplane substrateaccording to an embodiment of the present disclosure.

FIG. 9 is a vertical cross-sectional view of a backplane that is formedby forming various dielectric material layers on the backplane accordingto an embodiment of the present disclosure.

FIG. 10 is a vertical cross-sectional view of the backplane afterformation and patterning of an optional protective layer including anoptical protection material according to an embodiment of the presentdisclosure.

FIG. 11 is a vertical cross-sectional view of the backplane afterformation of first conductive bonding structures on a first subset ofhorizontal stepped surfaces according to an embodiment of the presentdisclosure.

FIG. 12 is a vertical cross-sectional view of the backplane whilebonding a first subset of the first light emitting devices on a firsttransfer substrate to the first conductive bonding structures on a firstsubset of horizontal stepped surfaces of the backplane according to anembodiment of the present disclosure.

FIG. 13 is a vertical cross-sectional view of the backplane and thefirst transfer substrate while detaching a light emitting device amongthe first subset of the first light emitting devices employing laserirradiation and ablation of a portion of the release layer in the firsttransfer substrate according to an embodiment of the present disclosure.

FIG. 14 is a vertical cross-sectional view of the backplane afterseparating the first transfer substrate according to an embodiment ofthe present disclosure.

FIG. 15 is a vertical cross-sectional view of the backplane afteraligning a second transfer substrate with second light emitting devicesthereupon according to an embodiment of the present disclosure.

FIG. 16 is a vertical cross-sectional view of the backplane and thesecond transfer substrate while detaching a light emitting device amonga first subset of the second light emitting devices employing laserirradiation and ablation of a portion of the release layer in the secondtransfer substrate according to an embodiment of the present disclosure.

FIG. 17 is a vertical cross-sectional view of the backplane afterseparating the second transfer substrate according to an embodiment ofthe present disclosure.

FIG. 18 is a vertical cross-sectional view of the backplane and a thirdtransfer substrate while detaching a light emitting device among a firstsubset of third light emitting devices employing laser irradiation andablation of a portion of the release layer in the third transfersubstrate according to an embodiment of the present disclosure.

FIG. 19 is a vertical cross-sectional view of the backplane afterseparating the third transfer substrate according to an embodiment ofthe present disclosure.

FIG. 20 is a vertical cross-sectional view of the backplane and a fourthtransfer substrate while detaching a sensor device among a first subsetof sensor devices employing laser irradiation and ablation of a portionof the release layer in the fourth transfer substrate according to anembodiment of the present disclosure.

FIG. 21 is a vertical cross-sectional view of the backplane afterseparating the fourth transfer substrate according to an embodiment ofthe present disclosure.

FIG. 22 is a vertical cross-sectional view of a first exemplary lightemitting device assembly after formation of a transparent encapsulationdielectric layer according to an embodiment of the present disclosure.

FIG. 23 is a vertical cross-sectional view of an alternate embodiment ofthe first exemplary light emitting device assembly after formation ofconductive interconnect structures according to an embodiment of thepresent disclosure.

FIG. 24 is an alternative embodiment of the devices on initial growthsubstrates according to an embodiment of the present disclosure.

FIG. 25 is a vertical cross-sectional view of another alternateembodiment of the first exemplary light emitting device assemblyaccording to an embodiment of the present disclosure.

FIG. 26 is a vertical cross-sectional view of yet another alternateembodiment of the first exemplary light emitting device assemblyaccording to an embodiment of the present disclosure.

FIG. 27 illustrates a processing step in an alternate embodiment of thepresent disclosure in which a dummy substrate is disposed above topsurfaces of bonded light emitting devices.

FIG. 28 illustrates a processing step in an alternate embodiment of thepresent disclosure in which the dummy substrate presses against bondedlight emitting diodes while solder balls are heated to a reflowtemperature.

FIG. 29 illustrates still another alternate embodiment of the firstexemplary light emitting device assembly according to an embodiment ofthe present disclosure.

FIG. 30 illustrates an exemplary transfer pattern and an exemplarytransfer sequence for transferring four different types of devices fromfour transfer substrates to four backplanes.

FIGS. 31A-31E are a schematic sequence for transfer of light emittingdiodes according to the exemplary transfer pattern illustrated in FIG.30.

FIGS. 32A-32N are sequential vertical cross-sectional views illustratinga process for formation of a second exemplary light emitting deviceassembly according to an embodiment of the present disclosure.

FIGS. 33A-33N are sequential vertical cross-sectional views illustratinga process for formation of a third exemplary light emitting deviceassembly according to an embodiment of the present disclosure.

FIGS. 34A-34N are sequential vertical cross-sectional views illustratinga process for formation of a fourth exemplary light emitting deviceassembly according to an embodiment of the present disclosure.

FIGS. 35A-35N are sequential vertical cross-sectional views illustratinga process for formation of a fifth exemplary light emitting deviceassembly according to an embodiment of the present disclosure.

FIG. 36 is an exemplary structure for formation of red-light emittingdiodes after formation of a dielectric material layer according to anembodiment of the present disclosure.

FIG. 37 is the exemplary structure for formation of red-light emittingdiodes after formation of conductive bonding structures according to anembodiment of the present disclosure.

FIG. 38 is an isolated red-light emitting diode subpixel aftersingulation and removal of an underlying substrate according to anembodiment of the present disclosure.

FIG. 39 is an assembly of a backplane and an array of pixels includinglight emitting diodes in case each of the light emitting diodes areprovided with a single conductive bonding structure.

FIG. 40A is the assembly of the backplane and the array of pixels afterapplication of an insulating inter-die fill material layer according toan embodiment of the present disclosure.

FIG. 40B is the assembly of the backplane and the array of pixels afterformation of a front side transparent conductive oxide layer and atransparent dielectric protection layer according to an embodiment ofthe present disclosure.

FIG. 41 is a vertical cross-sectional view of a first exemplary planarmaterial layer stack that can be formed over a substrate to providelight emitting diodes that emit light at a peak wavelength in a rangefrom 600 nm to 750 nm according to an embodiment of the presentdisclosure.

FIG. 42 is a vertical cross-sectional view of a second exemplary planarmaterial layer stack that can be formed over a substrate to providelight emitting diodes that emit light at a peak wavelength in a rangefrom 600 nm to 750 nm according to an embodiment of the presentdisclosure.

FIG. 43 is a vertical cross-sectional view of an exemplary devicestructure for forming nanowire-containing light emitting diodes afterforming a patterned growth mask according to an embodiment of thepresent disclosure.

FIG. 44 is a vertical cross-sectional view of the exemplary devicestructure after forming nanowire cores according to an embodiment of thepresent disclosure.

FIG. 45 is a vertical cross-sectional view of the exemplary devicestructure after forming shell structures according to an embodiment ofthe present disclosure.

FIG. 46A is a vertical cross-sectional view of a magnified region M ofthe exemplary structure of FIG. 45. FIG. 46B is a transmission electronmicroscope (TEM) micrograph of a magnified region R of the exemplarystructure of FIG. 45.

FIG. 47 is a vertical cross-sectional view of the exemplary devicestructure after formation of a p-type outer shell layer according to anembodiment of the present disclosure.

FIG. 48 is a vertical cross-sectional view of the exemplary devicestructure after formation of a continuous p-type semiconductor materiallayer according to an embodiment of the present disclosure.

FIG. 49 is a vertical cross-sectional view of the exemplary devicestructure after formation of a transparent conductive oxide layer and areflector layer according to an embodiment of the present disclosure.

FIG. 50 is graph showing external quantum efficiency of sample lightemitting devices employing the first exemplary planar material layerstack of FIG. 41 or the second exemplary planar material layer stack ofFIG. 42 according to an embodiment of the present disclosure.

FIG. 51 is a graph of emission intensity versus wavelength for thesecond exemplary planar material stack of FIG. 42 according to anembodiment of the present disclosure.

FIG. 52 shows a current—voltage plot of the device of an unencapsulatedsample 20 micron micro-LED employing the second exemplary planarmaterial stack of FIG. 42 at various operating current densityconditions according to an embodiment of the present disclosure.

FIG. 53 is a graph showing external quantum efficiency of sample lightemitting devices employing the exemplary device structure of FIG. 49according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

As stated above, the present disclosure is directed to an emissivedisplay panel including red-light emitting subpixels including indiumgallium nitride, and a method of manufacturing the same, the variousaspects of which are described below. Throughout the drawings, likeelements are described by the same reference numeral. The drawings arenot drawn to scale. Multiple instances of an element may be duplicatedwhere a single instance of the element is illustrated, unless absence ofduplication of elements is expressly described or clearly indicatedotherwise. Elements with the same reference numerals are presumed tohave the same composition and/or components unless expressly statedotherwise. Ordinals such as “first,” “second,” and “third” are employedmerely to identify similar elements, and different ordinals may beemployed across the specification and the claims of the instantdisclosure.

As used herein, a “light emitting device” refers to any device that isconfigured to emit light and includes, but is not limited to, a lightemitting diode (LED), a laser, such as a vertical-cavitysurface-emitting laser (VCSEL), and any other electronic device that isconfigured to emit light upon application of a suitable electrical bias.A light emitting device may be a vertical structure (e.g., a verticalLED) in which the p-side and n-side contacts are located on oppositesides of the structure or a lateral structure in which the p-side andn-side contacts are located on the same side of the structure. As usedherein, a “light emitting device assembly” refers to an assembly inwhich at least one light emitting device is structurally fixed withrespect to a support structure, which can include, for example, asubstrate, a matrix, or any other structure configured to provide stablemechanical support to the at least one light emitting device.

In the present disclosure, a method is provided for transferring anarray of devices (such as an array of light emitting devices or an arrayof sensor devices) from a growth substrate to a target substrate. Thetarget substrate can be any substrate on which formation of multipletypes of devices in any configuration is desired. In an illustrativeexample, the target substrate can be a backplane substrate such as anactive or passive matrix backplane substrate for driving light emittingdevices. As used herein, a “backplane substrate” refers to any substrateconfigured to affix multiple devices thereupon. In one embodiment, thecenter-to-center spacing of neighboring light emitting devices on thebackplane substrate can be is an integer multiple of thecenter-to-center spacing of neighboring light emitting devices on thegrowth substrate. The light emitting devices may include a plurality oflight emitting devices, such as a group of two light emitting devices,one configured to emit blue light and one configured to emit greenlight. The light emitting devices may include a group of three lightemitting devices, one configured to emit blue light, one configured toemit green light, and one configured to emit red light. As used herein,“neighboring light emitting devices” refer to a plurality of two or morelight emitting devices located in closer proximity than at least anotherlight emitting device. The method of the present disclosure can provideselective transfer of a subset of light emitting devices from a lightemitting device array on a growth substrate to the backplane substrate.

Referring to FIG. 1, devices (10B, 10G, 10R, 10S) can be fabricated onrespective initial growth substrates (101B, 101G, 101R, 101S) employingmethods known in the art. As used herein, an “initial growth substrate”refers to a substrate that is processed to form devices thereupon ortherein. The devices (10B, 10G, 10R, 10S) can include light emittingdevices (10B, 10G, 10R) and/or sensor devices 10S (e.g., photodetectors)and/or any other electronic devices. The light emitting devices (10B,10G, 10R) can be any type of light emitting devices, i.e., verticallight emitting devices, lateral light emitting devices, or anycombination thereof. Devices of the same type can be formed on eachinitial growth substrate (101B, 101G, 101R, 101S). The devices (10B,10G, 10R, 10S) can be formed as an array on the respective initialgrowth substrates (101B, 101G, 101R, 101S).

In one embodiment, the initial growth substrates (101B, 101G, 101R,101S) can include an absorbing substrate such as a silicon substrate. Asused herein, an “absorbing substrate” refers to a substrate that absorbsmore than 50% of light energy within the spectrum range includingultraviolet range, visible range, and infrared range. As used herein,“ultraviolet range” refers to the wavelength range from 10 nm to 400 nm;“visible range” refers to the wavelength range from 400 nm to 800 nm,and “infrared range” refers to the wavelength range from 800 nm to 1 mm.

If the initial growth substrates (101B, 101G, 101R, 101S) are absorbingsubstrates, each array of devices (10B, 10G, 10R, 10S) can betransferred to a respective transparent carrier substrates, or a“transparent substrate,” by full wafer transfer processes in which eacharray of devices (10B, 10G, 10R, 10S) is transferred to the respectivetransparent substrate in its entirety. As used herein, a “transparentsubstrate” refers to a substrate that transmits more than 50% of lightenergy at a wavelength within the spectrum range including ultravioletrange, visible range, and infrared range.

In one embodiment, devices (10B, 10G, 10R, 10S) can include lightemitting devices (10B, 10G, 10R). In one embodiment, each light emittingdevice (10B, 10G, 10R) can be configured to emit light of a single peakwavelength. It is understood that light emitting devices typically emitlight of a narrow wavelength band centered around the single wavelengthat which the intensity of light is at a maximum, and the wavelength of alight emitting device refers to the peak wavelength. For example, anarray of first light emitting devices 10B can be formed on a first-typegrowth substrate 100B, an array of second light emitting devices 10G canbe formed on a second-type growth substrate 100G, and an array of thirdlight emitting devices 10R can be formed on a third-type growthsubstrate 100R. In addition, an array of sensor devices 10S can beformed on a fourth-type growth substrate 100S. Alternatively, one ormore types of light emitting devices (10B, 10G, 10R) can be integratedlight emitting devices that are configured to emit light of at least twodifferent wavelengths. In one embodiment, the light emitting devices(10B, 10G, 10R) may comprise arrays of nanowires or othernanostructures.

Contact structures (not explicitly shown) such as contact pads areprovided on each light emitting device (10B, 10G, 10R). The contactstructures for each light emitting device (10B, 10G, 10R) can include ananode contact structure and a cathode contact structure. In case one ormore of the light emitting devices (10B, 10G, 10R) is an integratedlight emitting device configured to emit light of at least two differentwavelengths, a common contact structure (such as a common cathodecontact structure) can be employed. For example, a triplet of blue,green, and red light emitting devices embodied as a single integratedlight emitting device may have a single cathode contact.

The array of light emitting devices (10B, 10G, 10R) on each initialgrowth substrate (101B, 101G, 101R) is configured such that thecenter-to-center spacing of light emitting devices on a backplanesubstrate to which the light emitting devices are subsequentlytransferred is an integer multiple of the center-to-center spacing oflight emitting devices (10B, 10G, 10R) on the initial growth substrate(101B, 101G, 101R).

Each initial growth substrate (101B, 101G, 101R, 101S) and devices (10B,10G, 10R, 10S) thereupon can be diced into suitable sizes. Each dicedportion of the initial growth substrate (101B, 101G, 101R, 101S) isherein referred to as a growth substrate (100B, 100G, 100R, 100S).Assemblies of growth substrates (100B, 100G, 100R, 100S) with respectivedevices (10B, 10G, 10R, 10S) thereupon are thus generated. In otherwords, the growth substrates (100B, 100G, 100R, 100S) are either theentirety or the diced portions of the initial growth substrates (101B,101G, 101R, 101S), and an array of devices (10B, 10G, 10R, 10S) ispresent on each growth substrate (100B, 100G, 100R, 100S). The array ofdevices (10B, 10G, 10R, 10S) on each growth substrate (100B, 100G, 100R,100S) can be an array of devices of the same type.

Prior to, or after, each initial growth substrate (101B, 101G, 101R,101S) is singulated to corresponding growth substrates (100B, 100G,100R, 100S), each device (10B, 10G, 10R, 10S), e.g., a light emittingdevice, a group of light emitting devices, or a sensor device, can bemechanically isolated from one another by forming trenches between eachneighboring pair of the devices. In an illustrative example, if a lightemitting device array or a sensor array is disposed on an initial growthsubstrate (101B, 101G, 101R, 101S), the trenches can extend from thefinal growth surface of the light emitting device array or the sensorarray to the top surface of the initial growth substrate (101B, 101G,101R, 101S).

Various schemes may be employed to transfer each array of devices (10B,10G, 10R, 10S) to a respective transparent substrate, which is hereinreferred to as a transfer substrate. FIGS. 2-6 illustrate an exemplaryscheme that can be employed to transfer each array of devices (10B, 10G,10R, 10S) to a respective transparent substrate.

Referring to FIG. 2, first carrier substrates 200 can be optionallyemployed in case the contact structures on each device (10B, 10G, 10R,10S) are formed on the top side of each device (10B, 10G, 10R, 10S)during fabrication of the devices (10B, 10G, 10R, 10S) on the growthsubstrates (101B, 101G, 101R, 101S). The first carrier substrates 200can be any suitable substrate that can be bonded to the devices (10B,10G, 10R, 10S) and can provide structural support to the (10B, 10G, 10R,10S). Each as-grown array of devices (10B, 10G, 10R, 10S) and arespective growth substrate 100 is bonded to a first carrier substrate200. Thus, each growth substrate 100 can be bonded to a respective firstcarrier substrate 200 through the respective devices 10. In other words,the devices 10 are present between a growth substrate 100 and a firstcarrier substrate within each bonded structure (100, 10, 200). In anillustrative example, a first-type growth substrate 100B can be bondedto a first-type first carrier substrate 200B through first lightemitting devices 10B, a second-type growth substrate 100G can be bondedto a second-type first carrier substrate 200G through second lightemitting devices 10G, a third-type growth substrate 100R can be bondedto a third-type first carrier substrate 200R through third lightemitting devices 10R, and a fourth-type growth substrate 100S can bebonded to a fourth-type first carrier substrate 200S through the sensordevices 10S.

Referring to FIG. 3, each growth substrate 100 can be removed from thetransient bonded structure including the stack of the growth substrate100, an array of devices 10, and the first carrier substrate 200. Forexample, if the growth substrate 100 is a silicon substrate, the growthsubstrate 100 can be removed by a wet chemical etch process, grinding,polishing, splitting (for example, at a hydrogen implanted layer), or acombination thereof. For example, splitting of a substrate can beperformed by implanting atoms that form a weak region (such as hydrogenatoms implanted into a semiconductor material) and by applying asuitable processing conditions (for example, an anneal at an elevatedtemperature and/or mechanical force) to cause the substrate to splitinto two parts.

Referring to FIG. 4, a first bonding material layer 30A can be formed oneach first carrier substrate 200. The first bonding material layer 30Aincludes any bonding material that can be bonded to another bondingmaterial upon suitable treatment (such as application of heat and/orpressure). In one embodiment, the first bonding material layer 30A cancomprise a dielectric material such as silicon oxide,borophosphosilicate glass (BPSG), a spin-on glass (SOG) material, and/oran adhesive bonding material such as SU-8 or benzocyclobutene (BCB). Thethickness of the first bonding material layer 30A can be in a range from50 nm to 5 micron, although lesser and greater thicknesses can also beemployed. In one embodiment, the first bonding material layer 30A can bea silicon oxide layer having a thickness of about 1 micron. The firstbonding material layer 30A can be formed by a suitable deposition methodsuch as chemical vapor deposition or spin coating.

Transfer substrates 300 are provided. As used herein, a “transfersubstrate” refers to a substrate from which at least one device istransferred to a target substrate, which can comprise a backplanesubstrate. In one embodiment, each transfer substrate 300 can be asecond carrier substrate, which can be employed to receive an array ofdevices from a respective first carrier substrate 200 and to carry thearray of devices until a subset of the devices are transferred to thetarget substrate in a subsequent process.

In some embodiments, the transfer substrates 300 can be opticallytransparent at a laser wavelength. The laser wavelength is thewavelength of the laser beam to be subsequently employed to transferdevices individually and selectively from a respective transfersubstrate 300 to the target substrate, and can be an ultravioletwavelength, a visible wavelength, or an infrared wavelength. In oneembodiment, the transparent substrates 300 can include sapphire, glass(silicon oxide), or other optically transparent material known in theart. In an alternative embodiment, the transfer substrates 300 can betransparent growth substrates or diced portions thereof. In some otherembodiments in which initial growth substrates are cleaved (for example,at a layer implanted with hydrogen or noble gas) to provide a thinsubstrate from which light emitting diodes are transferred to abackplane without use of transfer substrates, the initial growthsubstrates may absorb laser at the laser wavelength.

A release layer 20 and a second bonding material layer 30B can besequentially deposited on each transfer substrate 300. The release layer20 includes a material that can provide sufficient adhesion to thetransfer substrate 300 and is absorptive at the laser wavelength of thelaser beam to be subsequently employed during a subsequent selectivetransfer process. For example, the release layer 20 can includesilicon-rich silicon nitride or a semiconductor layer, such as a GaNlayer that can be heated by laser irradiation. The thickness of therelease layer 20 can be in a range from 100 nm to 1 micron, althoughlesser and greater thicknesses can also be employed.

The second bonding material layer 30B can comprise a dielectric materialsuch as silicon oxide. The thickness of the second bonding materiallayer 30B can be in a range from 50 nm to 5 micron, although lesser andgreater thicknesses can also be employed. In one embodiment, the secondbonding material layer 30B can be a silicon oxide layer having athickness of about 1 micron. The second bonding material layer 30B canbe formed by a suitable deposition method such as chemical vapordeposition or spin coating.

A transfer substrate 300 can be provided for each first carriersubstrate 200. For example, a first transfer substrate 300B can beprovided for the first-type first carrier substrate 200B; a secondtransfer substrate 300G can be provided for the second-type firstcarrier substrate 200G; a third transfer substrate 300R can be providedfor the third-type first carrier substrate 300R; and an additionaltransfer substrate 300S can be provided for the additional type firstcarrier substrate 300S. Multiple stacked structures can be formed, whichinclude a first stacked structure (300B, 20, 30B) including a stack ofthe first transfer substrate 300B, a release layer 20, and a secondbonding material layer 30B; a second stacked structure (300G, 20, 30B)including a stack of the second transfer substrate 300G, a release layer20, and a second bonding material layer 30B; a third stacked structure(300R, 20, 30B) including a stack of the third transfer substrate 300R,a release layer 20, and a second bonding material layer 30B; and anadditional stacked structure (300S, 20, 30B) including a stack of theadditional transfer substrate 300S, a release layer 20, and a secondbonding material layer 30B.

The combination of the array of first light emitting devices 10B and thefirst transfer substrate 300B is herein referred to as a first transferassembly (300B, 10B), the combination of the second light emittingdevices 10G and the second transfer substrate 300G is herein referred toas a second transfer assembly (300G, 10G), and the combination of thethird light emitting devices 10R and the third transfer substrate 300Ris herein referred to as a third transfer assembly (300R, 10R). Inaddition, the combination of the sensor devices 10S and the fourthtransfer substrate 300S is herein referred to as fourth transferassembly (300S, 10S).

Referring to FIG. 5, each pair of a first carrier substrate 200 and atransfer substrate 300 (which can be a second carrier substrate) can bebonded. For example, the second bonding material layer 30B can be bondedwith the respective first bonding material layer 30A on thecorresponding first carrier substrate 200 to form a bonding materiallayer 30. Each bonded assembly comprises a first transfer substrate 300,a release layer 20, a bonding material layer 30, and an array of devices10.

Referring to FIG. 6, a first carrier substrate 200 is removed from eachbonded assembly (300, 20, 30, 200), for example, by polishing, grinding,cleaving, and/or chemical etching. Each array of devices 20 can bedisposed on a transfer substrate 300, which is a transparent carriersubstrate with a release layer 20 thereupon, i.e., between thetransparent carrier substrate and the array of devices 20.

Referring to FIG. 7, each array of devices 10 on a respective transfersubstrate 300 can be arranged such that each device 10 is laterallyspaced from neighboring devices 10 by trenches. For example, the arrayof first light emitting devices 10B on the first transfer substrate 300Bcan be laterally spaced from one another by trenches. Optionally, afirst optical protection material layer 17B can be applied to fill thegaps among the first light emitting devices 10B. Similarly, an opticalprotection material layer can be applied to fill the gaps among eacharray of devices 10 on other transfer substrates (300G, 300R, 300S).Each optical protection material layer comprises a material that absorbsor scatters light at the laser wavelength of the laser beam to besubsequently employed. Each optical protection material layer caninclude, for example, silicon-rich silicon nitride, an organic orinorganic antireflective coating (ARC) material, or a photoresistmaterial. Each optical protection material layer can be formed such thatthe outside surfaces of the devices 10 are not covered by the opticalprotection material layer. The optical protection material layers can beformed, for example, by spin coating or by a combination of depositionand a recess etch.

Each assembly (300, 20, 30, 10) comprising a transfer substrate 300 andan array of devices 10 can further comprise a release layer 20contacting the respective transfer substrate 300 and comprising amaterial that absorbs light at a wavelength selected from ultravioletrange, visible range, and infrared range, and a bonding material layer30 contacting the release layer 20 and the respective array of devices10.

Referring to FIG. 8, a backplane substrate 400 is provided. Thebackplane substrate 400 is a substrate onto which various devices can besubsequently transferred. In one embodiment, the backplane substrate 400can be a substrate of silicon, glass, plastic, and/or at least othermaterial that can provide structural support to the devices to besubsequently transferred thereupon. In one embodiment, the backplanesubstrate 400 may be a passive backplane substrate, in which metalinterconnect structures 440 comprising metallization lines are present,for example, in a criss-cross grid and active device circuits are notpresent. In another embodiment, the backplane substrate 400 may be anactive backplane substrate, which includes metal interconnect structures440 as a criss-cross grid of conductive lines and further includes adevice circuitry at one or more intersections of the criss-cross grid ofconductive lines. The device circuitry can comprises one or moretransistors.

Referring to FIG. 9, a backplane 401 including stepped horizontalsurfaces is formed. As used herein, “stepped horizontal surfaces” referto a set of horizontal surfaces that are vertically spaced apart andconnected by steps. In one embodiment, the stepped horizontal surfacescan be formed by adding various dielectric material layers 410 andadditional metal interconnect structures embedded in the additionaldielectric material layers 410 to the backplane substrate 400. In oneembodiment, the various dielectric material layers 410 can comprise aplurality of portions of an upper dielectric material layer 413overlying the dielectric material matrix, a plurality of portions of anintermediate dielectric material layer 412 interposed between the upperdielectric material layer 413 and the dielectric material matrix, and aplurality of portions of a lower dielectric material layer 411interposed between the intermediate dielectric material layer 412 andthe dielectric matrix. Alternatively, surface portions of the backplanesubstrate 401 as provided at the processing step of FIG. 8 can berecessed to different depths to form the backplane 401 including steppedhorizontal surfaces. The stepped horizontal surfaces can be provided ata top side of the backplane 401.

A first subset of the stepped horizontal surfaces can be located withina first horizontal surface plane HSP1, which is the horizontal planecontaining the topmost horizontal surfaces of the backplane 401. Asecond subset of the stepped horizontal surfaces can be located within asecond horizontal surface plane HSP2, which may be more proximal to abackside surface 409 of the backplane 401 than the first subset ofstepped horizontal surfaces is to the backside surface 409 of thebackplane 401. A third subset of the stepped horizontal surfaces can belocated within a third horizontal surface plane HSP3, which may be moreproximal to the backside surface 409 of the backplane 401 than thesecond subset of stepped horizontal surfaces is to the backside surface409 of the backplane 401. An additional subset of the stepped horizontalsurfaces can be located within an additional horizontal surface planeHSP4, which may be more proximal to the backside surface 409 of thebackplane 401 than the third subset of stepped horizontal surfaces is tothe backside surface 409 of the backplane 401. The first subset of thestepped horizontal surfaces can be formed in a first region R1, thesecond subset of the stepped horizontal surfaces can be formed in asecond region R2, the third subset of the stepped horizontal surfacescan be formed in a third region R3, and the additional subset of thestepped horizontal surfaces can be formed in a fourth region R4. Thefirst region R1 includes locations at which first type devices, such asfirst light emitting devices 10B, are to be subsequently attached. Thesecond region R2 includes locations at which second type devices, suchas second light emitting devices 10G, are to be subsequently attached.The third region R3 includes locations at which third type devices, suchas third light emitting devices 10R, are to be subsequently attached.The fourth region R4 includes locations at which fourth type devices,such as sensor devices 10S, are to be subsequently attached.

In one embodiment, horizontal top surfaces of the upper dielectricmaterial layer 413 can constitute the first subset of the steppedhorizontal surfaces, horizontal top surfaces of the intermediatedielectric material layer 412 can constitute the second subset of thestepped horizontal surfaces, horizontal top surfaces of the lowerdielectric material layer 411 can constitute the third subset of thestepped horizontal surfaces, and physically exposed surfaces of thebackplane substrate 400 can constitute the fourth subset of the steppedhorizontal surfaces.

A bond pad 420 can be provided d at each location at which a device isto be subsequently bonded. For example, the bond pads 420 can be formedat each intersection of the criss-cross lines of the metal interconnectstructures 440 in the backplane 401. The bond pads 420 cam comprisemetallic pads including a metallic material such as Sn, AuSn, SAC, orother solderable metal. Additionally or alternatively, the bond pads 420can comprise Cu or Au or other metal that can, through athermocompression process, form a contact with another metal. The bondpads 420 can be embedded within the backplane 401 as components of themetal interconnect structures 440, or can be formed on top of dielectricsurfaces of the backplane 401.

In one embodiment, the center-to-center spacing of bond pads 420 on thebackplane 401 can be an integer multiple of the center-to-center spacingof the devices 10 on a respective growth substrate 100, on a respectivefirst carrier substrate 200, or on a respective transfer substrate 300.

In one embodiment, the backplane 401 can comprise metal interconnectstructures 440 embedded within a dielectric material matrix. The bondpads 420 are electrically connected to a respective metal interconnectstructure 440 within the backplane 440. As used herein, a first elementis “electrically connected to” a second element if the first element iselectrically shorted to the second element.

In one embodiment, the bond pads 420 on the backplane 401 can beconfigured to align with contact pads on the devices 10 (such as lightemitting devices). One or more bond pads 401 may be provided in a group.For example, if a device 10 to be transferred to the backplane 401comprises a plurality of red, green, and blue light emitting diodes(LEDs), there may be a group of four bond pads 420 arranged in alignmentwith contact pads on the LED. For example, the group of bond pads 410can include an anode contact for the red LED, an anode contact for theblue LED, an anode contact for the green LED, and a cathode contact. Forexample, if a device 10 to be transferred to the backplane 401 comprisesa single LED, there may be a group of two bond pads 420 arranged inalignment with contact pads on the LED.

Referring to FIG. 10, a protective layer 422 including an opticalprotection material can be optionally formed on the side of thebackplane 401. The protective layer 422 includes a material that absorbsor scatters light at the laser wavelength of the laser beam to besubsequently employed. In one embodiment, the protective layer 422 caninclude a dielectric material such as silicon-rich silicon nitride or anantireflective coating material. The thickness of the protective layer422 can be in a range from 200 nm to 2 microns, although lesser andgreater thicknesses can also be employed. The protective layer 422 canbe formed such that conductive bonding structures (i.e., contactstructures) to be subsequently formed can contact the bond pads 420.Suitable openings can be formed in the protective layer 422. In oneembodiment, all openings in the protective layer 422 can be formed inthe same patterning step. In another embodiment, the opening in theprotective layer 422 can be sequentially formed, for example,immediately before formation of each set of conductive bondingstructures.

Referring to FIG. 11, conductive bonding structures (430B, 430G, 430R,430S) can be formed on the horizontal stepped surfaces located on thetop side of the backplane 401. The conductive bonding structures 430 caninclude first conductive bonding structures 430B that are formed on thefirst subset of horizontal stepped surfaces in the first region R1,second conductive bonding structures 430G that are formed on the secondsubset of horizontal stepped surfaces in the second region R2, thirdconductive bonding structures 430R that are formed on the third subsetof horizontal stepped surfaces in the third region R3, and additionalconductive bonding structures 430S that are formed on the fourth subsetof horizontal stepped surfaces in the fourth region R1.

The first conductive bonding structures 430B are formed at locations atwhich transfer of first light emitting devices 10B is desired. Thesecond conductive bonding structures 430G are formed at locations atwhich transfer of second light emitting devices 10G is desired. Thethird conductive bonding structures 430R are present at locations atwhich transfer of third light emitting devices 10R is desired. Theadditional conductive bonding structures 430S are present at locationsat which transfer of sensor devices 10S is desired.

In one embodiment, each of the conductive bonding structures 430 cancomprise a metal stack that can bond with the bond pads 420 provided onthe backplane 401. In one embodiment, the conductive bonding structures430 can comprise copper and/or gold, and the bonding pads can be formedof Sn. In one embodiment, the conductive bonding structures 430 cancomprise a layer of Au, and the bond pads 420 can be formed of AuSn oran Sn—Ag—Cu alloy. In another embodiment, the conductive bondingstructures 430 can be formed of copper, and the bond pads can be formedof copper. The conductive bonding structures 430 are electricallyconnected to a respective the metal interconnect structure 440 withinthe backplane 401. In general, various conductive bonding structuresthat can be employed for the purposes of the present disclosure caninclude (1) a lower conductive material (such as copper or aluminum thatis electrically attached to the circuitry of the backplane), (2) one ormore thin layers for adhesion, which covers the lower conductivematerial and provides a diffusion barrier (such as a TiPt layer), and(3) a solderable material (such as pure tin or indium, or alloys such asAuSn or SAC).

In one embodiment, the conductive bonding structures 430 can be employedto electrically and mechanically join various devices to be transferredto the backplane 401. The various devices can include light emittingdiode (LED) subpixels, sensor pixels, and other electronic elements.Additional contacts can be formed on other horizontal surfaces of theset of stepped horizontal surfaces at this step, or can be formed atsubsequent processing steps.

The various conductive bonding structures (which include the conductivebonding structures 430) may be formed on multiple horizontal planes thatare vertically offset. For example, for a three-color RGB display panelcomprising sensors, the various conductive bonding structures can bearranged in four different horizontal planes. In an illustrativeexample, the conductive bonding structures of the blue subpixels in thedisplay panel can be located on a first plane such as the firsthorizontal surface plane HSP1 containing the first subset of the steppedhorizontal surfaces. The various conductive bonding structures for allof the green subpixels can be located on a second plane such as thesecond horizontal surface plane HSP2 containing the second subset of thestepped horizontal surfaces. The second plane can be a certain distance,for example, 2 micron, lower than the first plane. The variousconductive bonding structures for all of the red subpixels can belocated on a third plane such as the third horizontal surface plane HSP3containing the third subset of the stepped horizontal surfaces. Thethird plane can be, for example, 4 micron lower than the first contactplane. The conductive bonding structures for all of the sensor subpixelscan be formed on a fourth plane such as the additional horizontalsurface plane HSP1 containing the additional subset of the steppedhorizontal surfaces. The fourth plane can be, for example, 6 micronslower than the first contact plane. A display panel with a greaternumber of colors than three colors, such as a four-color display panelor a five-color display panel, can be formed in the same manner. One ofthe advantage a display panel with more than three colors is that such adisplay panel can be less sensitive to non-uniform or dead pixels.

Each of the second conductive bonding structures 430G can have the samematerial stack (or the same material composition) as any embodiment ofthe first conductive bonding structures 430B. The second conductivebonding structures 430G are electrically connected to a respective themetal interconnect structure 440 within the backplane 401. In oneembodiment, the second conductive bonding structures 430G can beemployed to electrically and mechanically join various devices to betransferred to the backplane 401. In one embodiment, the secondconductive bonding structures 430G can have a greater height than thefirst conductive bonding structures 430B. In other words, the firstconductive bonding structures 430B can have a lesser height than thesecond conductive bonding structures 430G.

Each of the third conductive bonding structures 430R can have the samematerial stack (or the same material composition) as any embodiment ofthe first conductive bonding structures 430B or the second conductivebonding structures 430G. The third conductive bonding structures 430Rare electrically connected to a respective the metal interconnectstructure 440 within the backplane 401. In one embodiment, the thirdconductive bonding structures 430R can be employed to electrically andmechanically join various devices to be transferred to the backplane401. In one embodiment, the third conductive bonding structures 430R canhave a greater height than the second conductive bonding structures430G. In other words, the second conductive bonding structures 430G canhave a lesser height than the third conductive bonding structures 430R.

Each of the additional conductive bonding structures 430S can have thesame material stack (or the same material composition) as any embodimentof the first conductive bonding structures 430B or the second conductivebonding structures 430G or the third conductive bonding structures 430R.The additional conductive bonding structures 430S are electricallyconnected to a respective the metal interconnect structure 440 withinthe backplane 401. In one embodiment, the additional conductive bondingstructures 430S can be employed to electrically and mechanically joinvarious devices to be transferred to the backplane 401. In oneembodiment, the additional conductive bonding structures 430S can have agreater height than the third conductive bonding structures 430R. Inother words, the third conductive bonding structures 430R can have alesser height than the additional conductive bonding structures 430S.

Referring to FIG. 12, an assembly comprising a first transfer substrate301B and first light emitting devices 10B that emits light of a firstwavelength is disposed on the backplane 401 so that a first subset 11Bof the first light emitting devices 10B contacts the first conductivebonding structures 430B and a second subset 12B of the first lightemitting devices 10B does not contact any conductive bonding structure.The assembly comprising the first transfer substrate 301B and the firstlight emitting devices 10B is aligned to the backplane 401 so that thecontact pads (not shown) of the first subset 11B of the first lightemitting devices 10B contact respective first conductive bondingstructures 430B. Specifically, the array of the first light emittingdevices 10B can be aligned over the backplane 401 such that each bondpad 420 and a corresponding contact pad of an overlying first lightemitting device 10B contact the first conductive bonding structure 430Blocated therebetween.

The first subset 11B of the first light emitting devices 10B on thefirst transfer substrate 301B is bonded to the first conductive bondingstructures 430B, which are located on the first subset of horizontalstepped surfaces of the backplane 401. In one embodiment, the bond pads420 can be solderable bond pad, and a heat cycle can be applied to thebackplane 401 and the first transfer substrate 301B such that a soldermaterial reflows and the bond pads 420 are attached to the firstconductive bonding structures 430B. In one embodiment, the bond pads 420can be cold bonding bond pad, and the first conductive bondingstructures 430B can be metal stud bumps such as Cu stud bumps. In thiscase, a mechanical force is applied such that each bond pad 420 and acorresponding first conductive bonding structure 430B mate with eachother. Optionally, the first transfer substrate 301B can be thinned to athickness less than 100 microns prior to alignment with the backplane401.

Referring to FIG. 13, each first light emitting device 10B that isbonded to the first conductive bonding structures 430B can bedissociated from the first transfer substrate 301B individually, whilefirst light emitting devices 10B that are not bonded to the firstconductive bonding structures 430B remain intact, i.e., are notdetached. The set of the first light emitting devices 10B that arebonded to the first conductive bonding structures 430B is the firstsubset 11B of the first light emitting devices 10B, and the set of firstlight emitting devices 10B that are not bonded to the first conductivebonding structures 430B is the second subset 12B of the first lightemitting devices 10B. Each first light emitting device 10B among thefirst subset 11B of the first light emitting devices 10B can be detachedemploying targeted laser irradiation emitted by a laser 477. Thematerial of the release layer 20 is selected such that the laser beam isabsorbed by the release layer 20. The size of the laser beam, or thesize of the raster area of the laser beam if the laser beam is rastered,can be selected to substantially match the area of a single first lightemitting device 10B. The first optical protection material layer 17B, ifpresent, can absorb or reflect the portion of the laser beam thatcollaterally impinges thereupon. In one embodiment, the irradiatedportion of the release layer 20 can be ablated. Further, a portion ofthe bonding material layer 30 that underlies the ablated portion of therelease layer 20 can be collaterally ablated or structurally damagedduring the laser irradiation.

Each portion of the release layer 20 that overlies the first subset 11Bof the first light emitting devices 10B is irradiated by the laser beamsequentially, i.e., one at a time. The portions of the release layer 20that are irradiated by the laser beam are collectively referred to asfirst portions of the release layer 20, while the portions of therelease layer 20 that are not irradiated by the laser beam arecollectively referred to as second portions of the release layer 20. Thefirst portions of the release layer 20 that overlies the first subset11B of the first light emitting devices 10B are selectively andsequentially removed, while the second portions of the release layer 20that overlie the second subset 12B of the first light emitting devices10B are not removed. The first transfer substrate 301B comprises amaterial that is optically transparent at the laser wavelength.

In one embodiment, the release layer 20 can comprise silicon nitride,the laser wavelength can be an ultraviolet wavelength (such as 248 nm or193 nm), and irradiating the first portions of the release layer 20 withthe laser beam ablates the first portions of the release layer 20. Theprocess of selectively removing the first portions of the release layer20 while not removing the second portions of the release layer 20 isherein referred to as an area-selective laser lift-off process or adie-selective laser lift-off process. The size of the area of laserirradiation (i.e., the shot size) of the laser beam can be selected suchthat the area of the laser irradiation is slightly greater than the areaof each first light emitting device 10B (or a plurality of first lightemitting devices in case multiple first light emitting devices 10B aretransferred at the same time). Only the first subset 11B of first lightemitting devices 10B, i.e., the subset of the first light emittingdevices 10B (or groups of first light emitting devices 10B) which havetheir respective conductive contact structures 430B bonded to theunderlying bond pads 420, is processed by the selective laser lift-offprocess. The laser beam is steered away from the second subset 12B ofthe first light emitting devices 10B that are not bonded to thebackplane 401.

Referring to FIG. 14, after all first portions of the release layer 20overlying the first subset 11B of first light emitting devices 10B areremoved, the first transfer substrate 301B can be separated from thebackplane 401 by pulling the first transfer substrate 301B and/or thebackplane 401 from each other. In one embodiment, a remnant portion 30Fof the bonding material layer 30 can be formed on at least one of thefirst subset 11B of the first light emitting devices 10B after the firstportions of the release layer 20 are irradiated with the laser beam. Inanother embodiment, the portions of the bonding material layer 30underneath the irradiated portions of the release layer 20 can beablated or liquefied and flow out, for example, along sidewalls of anunderlying first light emitting device 10B. If any portion of thebonding material layer 30 remains underneath the irradiated portions ofthe release layer 20, the periphery of such a portion can be fracturedwhile the assembly comprising the first transfer substrate 301B and thesecond subset 12B of the first light emitting devices 10B is separatedfrom the backplane 401. The separation of the assembly comprising thefirst transfer substrate 301B and the second subset 12B of the firstlight emitting devices 10B from the backplane 401 can be performed whilethe first subset 11B of the first light emitting devices 10B remainsbonded to the first conductive bonding structures 430B.

The second subset 12B of the first light emitting devices 10B can beemployed to subsequently transfer another subset of the first lightemitting devices 10B to another backplane (not shown). The second lightemitting devices 10G on the second transfer substrate 300G (See FIG. 6)can be similarly employed to transfer a subset of the second lightemitting devices 10G to yet another backplane (not shown). The thirdlight emitting devices 10R on the third transfer substrate 300R (SeeFIG. 6) can be similarly employed to transfer a subset of the thirdlight emitting devices 10R to still another backplane (not shown). Thesensor devices 10S on the additional transfer substrate 300S (See FIG.6) can be similarly employed to transfer a subset of the sensor devices10S to even another backplane (not shown).

Optionally, a wet chemical clean process can be performed to removeresidual material from the backplane 401 and the first subset 11B offirst light emitting devices 10B thereupon. For example, dilutehydrofluoric acid can be employed to remove residual material from thesurfaces of the backplane 401 and the first subset 11B of first lightemitting devices 10B.

Referring to FIG. 15, an assembly comprising a second transfer substrate301G and second light emitting devices 10G that emits light of a secondwavelength is provided. The second wavelength is different from thefirst wavelength. For example, the first wavelength can be a wavelengthof blue light, and the second wavelength can be a wavelength of greenlight. The second light emitting devices 10G are not present inpositions that correspond to positions over the backplane 401 at whichthe first subset of the first light emitting devices 10B is present in aconfiguration in which the second light emitting devices 10G face thetop side of the backplane 401. In other words, the second light emittingdevices 10G are not present in areas that overlap with the areas of thefirst subset of the first light emitting devices 10B in a configurationin which the second light emitting devices 10G face downward and thefirst subset of the first light emitting devices 10B on the backplane401 face upward. In one embodiment, any second light emitting device 10Glocated in positions that would overlap with preexisting first devices10B on the backplane 401 can be removed from the second transfersubstrate 301G before the second transfer substrate 301G is aligned withthe backplane 401 for transfer of a subset of the second light emittingdevices 10G. Optionally, a second optical protection material layer 17Gcan be applied to fill the gaps among the second light emitting devices10G prior to removal of a subset of the second light emitting devices10G from overlapping locations. The second optical protection materiallayer 17G can have the same composition as the first optical protectionmaterial layer 17B. By ensuring that the second light emitting devices10G are not present in positions that correspond to positions over thebackplane 401 at which the first subset of the first light emittingdevices 10B is present, potential collision between second lightemitting devices 10G and the first subset of the first light emittingdevices 10B can be avoided when the second transfer substrate 301G issubsequently disposed on the backplane 401 to bond a subset of thesecond light emitting devices 10G.

After aligning the assembly of the second transfer substrate 301G andthe second light emitting devices 10G to the backplane 401, the assemblyof the second transfer substrate 301G and the second light emittingdevices 10G is disposed on the backplane 401 so that a first subset ofthe second light emitting devices 10G contacts the second conductivebonding structures 430G and a second subset of the second light emittingdevices 10G does not contact any conductive bonding structure. Thecontact pads (not shown) of the first subset of the second lightemitting devices 10G contact respective second conductive bondingstructures 430G. Specifically, the array of the second light emittingdevices 10G can be aligned over the backplane 401 such that each bondpad 420 and a corresponding contact pad of an overlying second lightemitting device 10G contact the second conductive bonding structure 430Glocated therebetween.

The second conductive bonding structures 430G are present at locationsat which transfer of second light emitting devices 10G is desired. Thefirst subset of the second light emitting devices 10G on the secondtransfer substrate 301G is bonded to the second conductive bondingstructures 430G, which are located on the second subset of horizontalstepped surfaces of the backplane 401. Each pair of a bond pad 420 andan overlying contact pads on the first subset of the second lightemitting devices 10G can be bonded through a respective secondconductive bonding structures 430G employing any of the bonding methodsdescribed above, i.e., the bonding methods that can be employed to bondpairs of a bond pad 420 and an overlying contact pads on the firstsubset of the first light emitting devices 10B through a respectivefirst conductive bonding structures 430B.

Subsequently, each second light emitting device 10G that is bonded tothe second conductive bonding structures 430G can be dissociated fromthe second transfer substrate 301G individually, while second lightemitting devices 10G that are not bonded to the second conductivebonding structures 430G remain intact, i.e., are not detached. The setof the second light emitting devices 10G that are bonded to the secondconductive bonding structures 430G is the first subset of the secondlight emitting devices 10G, and the set of second light emitting devices10G that are not bonded to the second conductive bonding structures 430Gis the second subset of the second light emitting devices 10G. Eachsecond light emitting device 10G among the first subset of the secondlight emitting devices 10G can be detached employing targeted laserirradiation emitted by a laser 477 in the same manner employed to detachthe first subset of the first light emitting devices 10B in a priorprocessing step. Thus, the first portions of the release layer 20 thatoverlies the first subset of the second light emitting devices 10G areselectively and sequentially removed, while the second portions of therelease layer 20 that overlie the second subset of the second lightemitting devices 10G are not removed. The second transfer substrate 301Gcomprises a material that is optically transparent at the laserwavelength. In one embodiment, the release layer 20 can comprise siliconnitride, the laser wavelength can be an ultraviolet wavelength (such as248 nm or 193 nm), and irradiating the first portions of the releaselayer 20 with the laser beam ablates the first portions of the releaselayer 20.

Referring to FIG. 17, after all first portions of the release layer 20overlying the first subset of the second light emitting devices 10G areremoved, the second transfer substrate 301G can be separated from thebackplane 401 by pulling the second transfer substrate 301G and/or thebackplane 401 from each other. In one embodiment, a remnant portion 30Fof the bonding material layer 30 can be formed on at least one of thefirst subset of the second light emitting devices 10G after the firstportions of the release layer 20 are irradiated with the laser beam. Inanother embodiment, the portions of the bonding material layer 30underneath the irradiated portions of the release layer 20 can beablated or liquefied and flow out, for example, along sidewalls of anunderlying second light emitting device 10G. If any portion of thebonding material layer 30 remains underneath the irradiated portions ofthe release layer 20, the periphery of such a portion can be fracturedwhile the assembly comprising the second transfer substrate 301G and thesecond subset of the second light emitting devices 10G is separated fromthe backplane 401. The separation of the assembly comprising the secondtransfer substrate 301G and the second subset of the second lightemitting devices 10G from the backplane 401 can be performed while thefirst subset of the second light emitting devices 10G remains bonded tothe second conductive bonding structures 430G.

The second subset of the second light emitting devices 10G can beemployed to subsequently transfer another subset of the second lightemitting devices 10G to another backplane (not shown). Optionally, a wetchemical clean process can be performed to remove residual material fromthe backplane 401 and the first subset of the first light emittingdevices 10B and the first subset of the second light emitting devices10G. For example, dilute hydrofluoric acid can be employed to removeresidual material from the surfaces of the backplane 401, the firstsubset of the first light emitting devices 10B, and the first subset ofthe second light emitting devices 10G.

Referring to FIG. 18, an assembly comprising a third transfer substrate301R and third light emitting devices 10R that emits light of a thirdwavelength is provided. The third wavelength is different from the firstwavelength and the second wavelength. For example, the first wavelengthcan be a wavelength of blue light, the second wavelength can be awavelength of green light, and the third wavelength can be a wavelengthof red light. The third light emitting devices 10R are not present inpositions that correspond to positions over the backplane 401 at whichthe first subset of the first light emitting devices 10B or the firstsubset of the second light emitting devices 10G is present in aconfiguration in which the third light emitting devices 10R face the topside of the backplane 401. In other words, the third light emittingdevices 10R are not present in areas that overlap with the areas of thefirst subset of the first light emitting devices 10B or the first subsetof the second light emitting devices 10G in a configuration in which thethird light emitting devices 10R face downward and the first subset ofthe first light emitting devices 10B and the first subset of the secondlight emitting devices 10G on the backplane 401 face upward.

In one embodiment, any third light emitting device 10R located inpositions that would overlap with preexisting devices (10B, 10G) on thebackplane 401 can be removed from the third transfer substrate 301Rbefore the third transfer substrate 301R is aligned with the backplane401 for transfer of a subset of the third light emitting devices 10R.Optionally, a third optical protection material layer 17R can be appliedto fill the gaps among the third light emitting devices 10R prior toremoval of a subset of the third light emitting devices 10R fromoverlapping locations. The third optical protection material layer 17Rcan have the same composition as the first optical protection materiallayer 17B. By ensuring that the third light emitting devices 10R are notpresent in positions that correspond to positions over the backplane 401at which the first subset of the first light emitting devices 10B andthe first subset of the second light emitting devices 10G are present,potential collision between the third light emitting devices 10R and thefirst subset of the first light emitting devices 10B or between thethird light emitting devices 10R and the first subset of the secondlight emitting devices 10G can be avoided when the third transfersubstrate 301R is subsequently disposed on the backplane 401 to bond asubset of the third light emitting devices 10R.

After aligning the assembly of the third transfer substrate 301R and thethird light emitting devices 10R to the backplane 401, the assembly ofthe third transfer substrate 301R and the third light emitting devices10R is disposed on the backplane 401 so that a first subset of the thirdlight emitting devices 10R contacts the third conductive bondingstructures 430R and a second subset of the third light emitting devices10R does not contact any conductive bonding structure. The contact pads(not shown) of the first subset of the third light emitting devices 10Rcontact respective third conductive bonding structures 430R.Specifically, the array of the third light emitting devices 10R can bealigned over the backplane 401 such that each bond pad 420 and acorresponding contact pad of an overlying third light emitting device10R contact the third conductive bonding structure 430R locatedtherebetween.

The third conductive bonding structures 430R are present only atlocations at which transfer of third light emitting devices 10R isdesired. The first subset of the third light emitting devices 10R on thethird transfer substrate 301R is bonded to the third conductive bondingstructures 430R, which are located on the third subset of horizontalstepped surfaces of the backplane 401. Each pair of a bond pad 420 andan overlying contact pads on the first subset of the third lightemitting devices 10R can be bonded through a respective third conductivebonding structures 430R employing any of the bonding methods describedabove, i.e., the bonding methods that can be employed to bond pairs of abond pad 420 and an overlying contact pads on the first subset of thefirst light emitting devices 10B through a respective first conductivebonding structures 430B.

Subsequently, each third light emitting device 10R that is bonded to thethird conductive bonding structures 430R can be dissociated from thethird transfer substrate 301R individually, while third light emittingdevices 10R that are not bonded to the third conductive bondingstructures 430R remain intact, i.e., are not detached. The set of thethird light emitting devices 10R that are bonded to the third conductivebonding structures 430R is the first subset of the third light emittingdevices 10R, and the set of third light emitting devices 10R that arenot bonded to the second conductive bonding structures 430R is thesecond subset of the third light emitting devices 10R. Each third lightemitting device 10R among the first subset of the third light emittingdevices 10R can be detached employing targeted laser irradiation emittedby a laser 477 in the same manner employed to detach the first subset ofthe first light emitting devices 10B in a prior processing step. Thus,the first portions of the release layer 20 that overlies the firstsubset of the third light emitting devices 10R are selectively andsequentially removed, while the second portions of the release layer 20that overlie the second subset of the third light emitting devices 10Rare not removed. The third transfer substrate 301R comprises a materialthat is optically transparent at the laser wavelength. In oneembodiment, the release layer 20 can comprise silicon nitride, the laserwavelength can be an ultraviolet wavelength (such as 248 nm or 193 nm),and irradiating the first portions of the release layer 20 with thelaser beam ablates the first portions of the release layer 20.

Referring to FIG. 19, after all first portions of the release layer 20overlying the first subset of the third light emitting devices 10R areremoved, the third transfer substrate 301R can be separated from thebackplane 401 by pulling the third transfer substrate 301R and/or thebackplane 401 from each other. In one embodiment, a remnant portion 30Fof the bonding material layer 30 can be formed on at least one of thefirst subset of the third light emitting devices 10R after the firstportions of the release layer 20 are irradiated with the laser beam. Inanother embodiment, the portions of the bonding material layer 30underneath the irradiated portions of the release layer 20 can beablated or liquefied and flow out, for example, along sidewalls of anunderlying third light emitting device 10R. If any portion of thebonding material layer 30 remains underneath the irradiated portions ofthe release layer 20, the periphery of such a portion can be fracturedwhile the assembly comprising the third transfer substrate 301R and thesecond subset of the third light emitting devices 10R is separated fromthe backplane 401. The separation of the assembly comprising the thirdtransfer substrate 301R and the second subset of the third lightemitting devices 10R from the backplane 401 can be performed while thefirst subset of the third light emitting devices 10R remains bonded tothe third conductive bonding structures 430R.

The second subset of the third light emitting devices 10R can beemployed to subsequently transfer another subset of the third lightemitting devices 10R to another backplane (not shown). Optionally, a wetchemical clean process can be performed to remove residual material fromthe backplane 401, the first subset of the first light emitting devices10B, the first subset of the second light emitting devices 10G, and thefirst subset of the third light emitting devices 10R. For example,dilute hydrofluoric acid can be employed to remove residual materialfrom the surfaces of the backplane 401, the first subset of the firstlight emitting devices 10B, the first subset of the second lightemitting devices 10G, and the first subset of the third light emittingdevices 10R.

It is understood that the order of bonding various devices can bepermutated to enable bonding of multiple types of devices havingdifferent heights and the same horizontal pitch, i.e., the sameperiodicity along the two horizontal directions. In general, thesequence of bonding different devices 10 and the height of therespective conductive bonding structures can be selected to avoidcollision between pre-existing bonded devices on the backplane 401 andthe new devices to be bonded. The horizontal plane including theinterface between the devices and the bonding material layer of thetransfer substrate that is disposed over the backplane 410 is locatedabove the topmost surfaces of the preexisting devices on the backplane401.

Referring to FIG. 20, an assembly comprising the additional transfersubstrate 301S and the sensor devices that sense at least one parameteris provided. The at least one parameter can be luminosity, pressure,temperature, and/or another physical parameter. The sensor devices 10Sare not present in positions that correspond to positions over thebackplane 401 at which the first subset of the first light emittingdevices 10B, the first subset of the second light emitting devices 10G,or the first subset of the third light emitting devices 10R is presentin a configuration in which the sensor devices 10S face the top side ofthe backplane 401. In other words, the sensor devices 10S are notpresent in areas that overlap with the areas of the first subset of thefirst light emitting devices 10B, the first subset of the second lightemitting devices 10G, or the first subset of the third light emittingdevices 10R in a configuration in which the sensor devices 10S facedownward and the first subset of the first light emitting devices 10B,the first subset of the second light emitting devices 10G, and the firstsubset of the third light emitting devices 10R on the backplane 401 faceupward. In one embodiment, any sensor device 10S located in positionsthat would overlap with preexisting devices (10B, 10G, 10R) on thebackplane 401 can be removed from the additional transfer 301S substratebefore the additional transfer substrate 301S is aligned with thebackplane 401 for transfer of a subset of the sensor devices 10S.Optionally, a fourth optical protection material layer 17S can beapplied to fill the gaps among the sensor devices 10S prior to removalof a subset of the sensor devices 10S from overlapping locations. Thefourth optical protection material layer 17S can have the samecomposition as the first optical protection material layer 17B. Byensuring that the sensor devices 10S are not present in positions thatcorrespond to positions over the backplane 401 at which the first subsetof the first light emitting devices 10B, the first subset of the secondlight emitting devices 10G, and the first subset of the third lightemitting devices 10R are present, potential collision between the sensordevices 10S and the light emitting devices (10B, 10G, 10R) can beavoided when the additional transfer substrate 301S is subsequentlydisposed on the backplane 401 to bond a subset of the sensor devices10S.

After aligning the assembly of the additional transfer substrate 301Rand the sensor devices 10S to the backplane 401, the assembly of theadditional transfer substrate 301S and the sensor devices 10S isdisposed on the backplane 401 so that a first subset of the sensordevices 10S contacts the additional conductive bonding structures 430Sand a second subset of the sensor devices 10S does not contact anyconductive bonding structure. The contact pads (not shown) of the firstsubset of the sensor devices 10S contact respective additionalconductive bonding structures 430S. Specifically, the array of thesensor devices 10S can be aligned over the backplane 401 such that eachbond pad 420 and a corresponding contact pad of an overlying sensordevice 10S contact the additional conductive bonding structure 430Slocated therebetween.

The additional conductive bonding structures 430S are present only atlocations at which transfer of sensor devices 10S is desired. The firstsubset of the sensor devices 10S on the additional transfer substrate301S is bonded to the additional conductive bonding structures 430S,which are located on the fourth subset of horizontal stepped surfaces ofthe backplane 401. Each pair of a bond pad 420 and an overlying contactpads on the first subset of the sensor devices 10S can be bonded througha respective additional conductive bonding structures 430S employing anyof the bonding methods described above, i.e., the bonding methods thatcan be employed to bond pairs of a bond pad 420 and an overlying contactpads on the first subset of the first light emitting devices 10B througha respective first conductive bonding structures 430B.

Subsequently, each sensor device 10S that is bonded to the additionalconductive bonding structures 430S can be dissociated from theadditional transfer substrate 301G individually, while sensor devices10S that are not bonded to the additional conductive bonding structures430S remain intact, i.e., are not detached. The set of the sensordevices 10S that are bonded to the additional conductive bondingstructures 430G is the first subset of the sensor devices 10S, and theset of sensor devices 10S that are not bonded to the second conductivebonding structures 430G is the second subset of the sensor devices 10S.Each sensor device 10S among the first subset of the sensor devices 10Scan be detached employing targeted laser irradiation emitted by a laser477 in the same manner employed to detach the first subset of the firstlight emitting devices 10B in a prior processing step. Thus, the firstportions of the release layer 20 that overlie the first subset of thesensor devices 10S are selectively and sequentially removed, while thesecond portions of the release layer 20 that overlie the second subsetof the sensor devices 10S are not removed. The additional transfersubstrate 301S comprises a material that is optically transparent at thelaser wavelength. In one embodiment, the release layer 20 can comprisesilicon nitride, the laser wavelength can be an ultraviolet wavelength(such as 248 nm or 193 nm), and irradiating the first portions of therelease layer 20 with the laser beam ablates the first portions of therelease layer 20.

Referring to FIG. 21, after all first portions of the release layer 20overlying the first subset of the sensor devices 10S are removed, theadditional transfer substrate 301S can be separated from the backplane401 by pulling the additional transfer substrate 301S and/or thebackplane 401 from each other. In one embodiment, a remnant portion 30Fof the bonding material layer 30 can be formed on at least one of thefirst subset of the sensor devices 10S after the first portions of therelease layer 20 are irradiated with the laser beam. In anotherembodiment, the portions of the bonding material layer 30 underneath theirradiated portions of the release layer 20 can be ablated or liquefiedand flow out, for example, along sidewalls of an underlying sensordevice 10S. If any portion of the bonding material layer 30 remainsunderneath the irradiated portions of the release layer 20, theperiphery of such a portion can be fractured while the assemblycomprising the additional transfer substrate 301S and the second subsetof the sensor devices 10S is separated from the backplane 401. Theseparation of the assembly comprising the additional transfer substrate301S and the second subset of the sensor devices 10S from the backplane401 can be performed while the first subset of the sensor devices 10Sremains bonded to the additional conductive bonding structures 430S.

The second subset of the sensor devices 10S can be employed tosubsequently transfer another subset of the sensor devices 10S toanother backplane (not shown). Optionally, a wet chemical clean processcan be performed to remove residual material from the backplane 401, thefirst subset of the first light emitting devices 10B, the first subsetof the second light emitting devices 10G, the first subset of the thirdlight emitting devices 10R, and the first subset of the sensor devices10S. For example, dilute hydrofluoric acid can be employed to removeresidual material from the surfaces of the backplane 401, the firstsubset of the first light emitting devices 10B, the first subset of thesecond light emitting devices 10G, the first subset of the third lightemitting devices 10R, and the first subset of the sensor devices 10S.

Referring to FIG. 22, the electronic components (light emitting devicesubpixels, sensors, or other components) may be encapsulated by atransparent encapsulation material. The transparent encapsulationmaterial increases the extraction of light from the light emittingdevice subpixels, increasing the amount of light emitted by the displaypanel. The transparent encapsulation material may provide a top surfaceof the display panel that has less peak-to-valley height variations. Atransparent material can be deposited over the backplane 401 to form atransparent encapsulation dielectric layer 470. The encapsulant may beany of a range of materials such as dielectric resins (such asbenzocyclobutene, polymethylmethacrylate, polybenzoxazole, orpolyimide), silicones, dielectrics (such as TiO₂ or SiO₂), orlow-melting temperature glasses or spin-on glasses.

The thicknesses of the conductive bonding structures and/or thethicknesses of the electronic component (light emitting device, sensor,or other electronic element) may be different for each of the groupingsof components. In an illustrative example of a three-color RGB displaypanel comprising sensors, the first light emitting devices 10B can beblue light emitting devices, the second light emitting devices can begreen light emitting devices, and the third light emitting devices canbe red light emitting devices. The blue light emitting device may have athickness of 6 microns and the first conductive bonding structure 430Bbetween the backplane substrate and the blue light emitting device maybe about 2 microns thick. The green light emitting device may have athickness of 7 microns and the second conductive bonding structure 430Gbetween the backplane substrate and the green light emitting device maybe 4 microns thick. The red light emitting device may have a thicknessof 8 microns and the third conductive bonding structure 430R between thebackplane substrate and the red light emitting device may be 5 micronsthick. The sensor device 10S may have a thickness of 8 microns and theadditional conductive bonding structure 430S between the backplanesubstrate and the sensor may be 7 microns thick. In this example, theheight of the distal face of the electronic component (face of the lightemitting device or sensor farthest from the backplane 430) above theface of the backplane substrate may be 8 microns, 11 microns, 13microns, and 15 microns, for the blue light emitting device, green lightemitting device, red light emitting device, and sensor, respectively.

In a display panel, the thicknesses of the conductive bonding structuresfor the electronic components (light emitting devices, sensors, etc) maybe different, or the thicknesses of the electronic components (lightemitting devices, sensors, etc) may be different, or a combinationthereof, as described in the example above.

The conductive bonding structures (430B, 430G, 430R, 430S) may beconfigured to make one or more electrical contacts to each elementaffixed to the backplane 401. In one embodiment, a green light emittingdevice subpixel may be affixed to the backplane substrate by twoconductive bonding structures. A first conductive bonding structureconnects the cathode of the green light emitting device to theelectronic circuitry in the backplane 430, and a second conductivebonding structures connects the anode of the light emitting device tothe electronic circuitry in the backplane 401. In one embodiment, thefirst and second conductive bonding structures may be located ondifferent horizontal planes. For example, the anode contact plane may be0.5 micron higher than the cathode contact plane. In one embodiment, thefirst and second conductive bonding structures may be differentthicknesses. For example, the anode bonding structure thickness may be0.5 um thicker than the cathode bonding structure.

In another embodiment, a blue light emitting device subpixel may beaffixed to the backplane 430 by one conductive bonding structure, whichmay be either an anode bonding structure or a cathode bonding structure.In another embodiment, a silicon photodetector device may be affixed tothe backplane 401 by two conductive bonding structures. In anotherembodiment, an array of three silicon photodetectors may be affixed tothe backplane 401 by six conductive bonding structures. In anotherembodiment, a silicon photodetector device may be affixed to thebackplane 430 by one conductive bonding structure, which may be eitheran anode or cathode bonding structure or a cathode bonding structure.

In one embodiment, a light emitting device configured to emit blue lightmay be formed adjacent to a light emitting device configured to emitgreen light and adjacent to a light emitting device configured to emitred light. In one embodiment, all contacts to the electronic devicesaffixed to the backplane 401 can be provided between the backplane 401and the electronic components, and the transparent encapsulationdielectric layer 470 can have a single top surface (i.e., beplanarized). In another embodiment, the transparent encapsulationdielectric layer 470 can be formed into a microlens array, for examplewith a domed surface over each electronic component.

The conductive bonding structures between electrical components (lightemitting device subpixels, sensors, or other components) and thebackplane 401 may comprise Ag, Al, Au, In, Sn, Cu, Ni, Bi, Sb. Theconductive bonding structures may comprise multiple layers comprisingmultiple metals or metal alloys. The conductive bonding structures fordifferent groupings of devices may comprise different metals or metalalloys. For example, the conductive bonding structures affixing the bluelight emitting devices to the backplane 401 may comprise AuSn, theconductive bonding structures affixing the green light emitting devicesto the backplane 401 may comprise NiSn, and the conductive bondingstructures affixing the red light emitting devices to the backplanesubstrate may comprise InSn.

The exemplary structure of FIG. 22 is a first exemplary light emittingdevice assembly that comprises a backplane 401 having stepped horizontalsurfaces at a top side. The stepped horizontal surfaces comprise a firstsubset of the stepped horizontal surfaces located within a firsthorizontal surface plane HSP1, a second subset of the stepped horizontalsurfaces located within a second horizontal surface plane HSP2 that ismore proximal to a backside surface 409 of the backplane 401 than thefirst subset of stepped horizontal surfaces is to the backside surface409 of the backplane 401, a third subset of the stepped horizontalsurfaces located within a third horizontal surface plane HSP3 that ismore proximal to the backside surface 409 of the backplane 401 than thesecond subset of stepped horizontal surfaces is to the backside surface409 of the backplane 401, and a fourth subset of the stepped horizontalsurfaces located within a fourth horizontal surface plane HSP4 that ismore proximal to the backside surface 409 of the backplane 401 than thethird subset of stepped horizontal surfaces is to the backside surface409 of the backplane 401. The height of each step between eachconsecutive plane can be in a range from 0 micron to 3 microns (forexample, in a range from 0.2 micron to 2 microns). The presence orabsence of finite step heights is dependent on methods employed forselectively attaching light emitting devices (or sensor devices), whichdepend on embodiments employed to implement the methods of the presentdisclosure. In other words, the steps may not be present in someembodiments, and all of the horizontal surface planes (HSP1, HSP2, HSP3,HSP4) can be located within the same horizontal plane in such cases. Thepresence of the steps facilitate formation of the topmost surfaces ofthe various electronic components (such as the light emitting devices(10B, 10G, 10R) and the sensor devices 10S) to be formed with lessheight differential than would be otherwise possible.

The integrated light emitting device assembly further comprisesconductive bonding structures (430B, 430G, 430R, 430S) located on thestepped horizontal surfaces of the backplane 401. The conductive bondingstructures (430B, 430G, 430R, 430S) can comprise first conductivebonding structures 430B contacting the first subset of the steppedhorizontal surfaces, second conductive bonding structures 430Gcontacting the second subset of the stepped horizontal surfaces, thirdconductive bonding structures 430R contacting the third subset of thestepped horizontal surfaces, and additional conductive bondingstructures 430S contacting the fourth subset of the stepped horizontalsurfaces.

The integrated light emitting device assembly can further comprise lightemitting devices (10B, 10G, 10R) bonded to the respective conductivebonding structures (430B, 430G, 430R, 430S). The light emitting devices(10B, 10G, 10R) comprise first light emitting devices 10B that emitlight of a first wavelength and overlie the first subset of the steppedhorizontal surfaces, second light emitting devices 10G that emit lightof a second wavelength and overlie the second subset of steppedhorizontal surfaces, and third light emitting devices 10R that emitlight of a third wavelength and overlie the third subset of steppedhorizontal surfaces.

The integrated light emitting device assembly can further comprisesensor devices 10S bonded to the backplane 410 through fourth conductivebonding structures 430S. The sensor devices 10S can overlie the fourthsubset of stepped horizontal surfaces.

The locations of the various bonded components (10B, 10G, 10R, 10S), theheights of the various conductive bonding structures (430B, 430G, 430R,430S), and the heights of the various stepped horizontal surfaces can becombined so that the height differential among the topmost surface ofthe bonded components (10B, 10G, 10R, 10S) as bonded to the backplane401 can be less than the height differential among the various bondedcomponents (10B, 10G, 10R, 10S). In one embodiment, a first horizontalinterfacial plane HIP1 including interfaces between the first lightemitting devices 10B and the first conductive bonding structures 403Bcan be more distal from the second horizontal surface plane HSP2 (orfrom any other horizontal reference plane such as the fourth horizontalsurface plane HSP4 or the backside surface 409) than a second horizontalinterface plane HIP2 between the second light emitting devices 10G andthe second conductive bonding structures 430G is to the secondhorizontal surface plane HSP2 (or from any other horizontal referenceplane such as the fourth horizontal surface plane HSP4 or the backsidesurface 409).

In one embodiment, the various conductive bonding structures (430B,430G, 430R, 430S) can have different heights to reduce the heightdifferential among the topmost surface of the bonded components (10B,10G, 10R, 10S). In one embodiment, the second conductive bondingstructures 430G can have a greater height than the first conductivebonding structures 430B. The third conductive bonding structures 430Rcan have a greater height than the second conductive bonding structures430G. The additional conductive bonding structures 430S can have agreater height than the third conductive bonding structures 430R. Theheight differential among the various conductive bonding structures(430B, 430G, 430R, 430S) can be optional provided that the inherentheight differential among the various bonded components (10B, 10G, 10R,10S), the step height differential among the stepped horizontal surfacesof the backplane 401, and the locations of the various bonded components(10B, 10G, 10R, 10S) can be combined to prevent collision amongsequential bonding of various transfer substrates (300B, 300G, 300R,300S).

In one embodiment, a first horizontal top plane HTP1 including topsurfaces of the first light emitting devices 10B can be more proximal tothe second horizontal surface plane HSP2 (or from any other horizontalreference plane such as the fourth horizontal surface plane HSP4 or thebackside surface 409) than a second horizontal top plane HTP2 includingtop surfaces of the second light emitting devices 10G is to the secondhorizontal surfaces plane HSP2 (or from any other horizontal referenceplane such as the fourth horizontal surface plane HSP4 or the backsidesurface 409). The second horizontal top plane HTP2 including topsurfaces of the second light emitting devices 10G can be more proximalto the second horizontal surface plane HSP2 (or from any otherhorizontal reference plane such as the fourth horizontal surface planeHSP4 or the backside surface 409) than a third horizontal top plane HTP3including top surfaces of the third light emitting devices 10R is to thesecond horizontal surfaces plane HSP2 (or from any other horizontalreference plane such as the fourth horizontal surface plane HSP4 or thebackside surface 409). The third horizontal top plane HTP3 including topsurfaces of the third light emitting devices 10R can be more proximal tothe second horizontal surface plane HSP2 (or from any other horizontalreference plane such as the fourth horizontal surface plane HSP4 or thebackside surface 409) than a fourth horizontal top plane HTP4 includingtop surfaces of the sensor devices 10S is to the second horizontalsurfaces plane HSP2 (or from any other horizontal reference plane suchas the fourth horizontal surface plane HSP4 or the backside surface409).

In one embodiment, the second light emitting devices 10G can have agreater height than the first light emitting devices 10B, the thirdlight emitting devices 10R can have a greater height than the secondlight emitting devices 10G, and the sensor devices 10S can have agreater height than the third light emitting devices 10R.

In one embodiment, the backplane 401 comprises metal interconnectstructures 440 embedded within a dielectric material matrix. Theconductive bonding structures (430B, 430G, 430R, 430S) are electricallyconnected to a respective metal interconnect structure 440 within thebackplane 401. The metal interconnect structures 440 can comprise bondpads 420 that are located on, or embedded within, the backplane 410. Thebond pads 420 contact a respective bottom surface of the conductivebonding structures (430B, 430G, 430R, 430S). In one embodiment, theconductive bonding structures (430B, 430G, 430R, 430S) can comprisesolder balls bonded to a respective bond pad 420 and to a respectivelight emitting device (10B, 10G, 10R) or to a respective sensor device10S.

In one embodiment, a remnant portion 30F of the bonding material layercan be present over one or more of the bonded components (10B, 10G, 10R,10S). For example, silicon oxide material portions can contact arespective top surface of the light emitting devices (10B, 10G, 10S),and can be laterally spaced from one another. In one embodiment, thetransparent encapsulation dielectric layer 470 can overlie the backplane401 and can embed the light emitting devices (10B, 10G, 10R) and thesensor devices 10S.

Optionally, a protective material layer 422 may be located on thestepped horizontal surfaces and sidewalls of the backplane 401. Theprotective material layer 422 can comprise a material that absorbs lightwithin a wavelength range that includes ultraviolet light, visiblelight, and infrared light. In one embodiment, the light emitting devices(10B, 10G, 10R) and/or the sensor devices 10S can be arranged in aperiodic array in which center-to-center distances of neighboring lightemitting devices (10B, 10G, 10R) along a horizontal direction areinteger multiples of a unit distance. In one embodiment, the periodicarray can be a rectangular array in which the light emitting devices(10B, 10G, 10R) and/or the sensor devices 10S are arranged at latticesites of a rectangular lattice.

Referring to FIG. 23, an alternative embodiment of the integrated lightemitting device assembly is shown. Conductive interconnect structures480 can be formed within the transparent encapsulation dielectric layer470, for example, by formation of line cavities and via cavities by acombination of lithographic patterning and at least one etch process,and by filling the line cavities and the via cavities with at least oneconductive material. Alternatively or additionally, conductiveinterconnect structures 480 can be formed over the transparentencapsulation dielectric layer 470, for example, by deposition of aconductive material layer and patterning of the conductive materiallayer by a combination of lithographic patterning and at least one etchprocess. The conductive interconnect structures 480 can electricallycontact one or more of the bonded components (10B, 10G, 10R, 10S). Forexample, the conductive interconnect structures 480 can be embeddedwithin the transparent encapsulation dielectric layer 470 and canelectrically contact a respective light emitting device (10B, 10G, 10R)and/or a respective sensor device 10S. In one embodiment, at least oneof the conductive interconnect structures 480 can be electricallyconnected to a metal interconnect structure 440 embedded within thebackplane 401.

In one embodiment, only a first part of the electrical contacts to theelectronic components (10B, 10G, 10R, 10S) can be provided by theconductive bonding structures (430B, 430G, 430R, 430S) formed betweenthe components (10B, 10G, 10R, 10S) and the backplane 401. A second partof the electrical contacts to the electrical components (10B, 10G, 10R,10S) can be provided by a top contact layer as embodied by theconductive interconnect structures 480. The conductive interconnectstructures 480 are formed over the electronic components (10B, 10G, 10R,10S), and can be embedded within the transparent encapsulationdielectric layer 470, and/or can be formed over the transparentencapsulation dielectric layer 470.

In one embodiment, the transparent encapsulation dielectric layer 470may partially planarize the top surface of a display panel thatincorporates the integrated light emitting device assembly of thepresent disclosure. Via cavities can be provided in the transparentencapsulation dielectric layer 470 directly over the top surface of eachelectronic component (10B, 10G, 10S), and a transparent conductive oxidesuch as ITO or AZO, silver nanowire mesh, silver mesh electrode, orother transparent or semitransparent contact structures can be providedover the encapsulant and electronic components, forming op contactstructures as embodied as the conductive interconnect structures 480.The top contact structures may be electrically joined to the backplane401 at some specific site on the backplane 401, for example, bywirebonding or by contact via structures that extend through transparentencapsulation dielectric layer 470. The top contact structures may be afull sheet contact which covers every electronic component (10B, 10G,10R, 10S) on the backplane 401, or may be patterned to provide multipletop contact structures to specific components or groups of components,in which case the top contact structures may be electrically joined tothe backplane 401 at several specific sites, e.g. by wirebonding or bycontact with a metal electrode formed on the backplane 401.

Referring to FIG. 24, an alternative embodiment of the devices (10B,10G, 10R, 10S) on growth substrates 500 is illustrated. In this case,the devices (10B, 10G, 10R, 10S) can be grown or fabricated from thegrowth substrates 500 employing device fabrication techniques known inthe art. For example, the growth substrates 500 can be a semiconductorsubstrate including a semiconductor material, which can be a compoundsemiconductor substrate (e.g., a GaAs or a GaN substrate), or aninsulating substrate, such as sapphire. Each growth substrate 500 can beprovided with an internal release layer 520, which can be, for example,an implanted material layer such as an implanted hydrogen layer, animplanted oxygen layer, an implanted nitrogen layer, or a layer formedby implantation of any other atomic species that facilitates cleavingupon irradiation by laser or local heating by other methods. Theinternal release layer 520 performs the function of the release layer 20discussed above.

Each growth substrate 500 can be provided with a source substrate 530,which can be a thin layer of the material of the growth substrate 500,and is thin enough to be fractured, ablated, or otherwise removed uponlaser irradiation of an adjoining portion of the internal release layer520. The thickness of the source substrate 530 can be in a range from 50nm to 3 microns, although lesser and greater thicknesses can also beemployed. In one embodiment, first light emitting devices 10B can bemanufactured over a first growth substrate 500B, second light emittingdevices 10G can be manufactured over a second growth substrate 500G,third light emitting devices 10R can be manufactured over a third growthsubstrate 500R, and sensor devices 10S can be manufactured over a fourthgrowth substrate 500S.

Referring to FIG. 25, the same processing sequences described above canbe employed to form an integrated light emitting device assembly. Aportion of the source substrate 530 is ablated during each laserirradiation process. Because a source substrate 530 is present on eachgrowth substrate 500, a remnant portion 530F of the source substrate 530can be present over the bonded components (10B, 10G, 10R, 10S) andwithin the transparent encapsulation dielectric layer 470.

The methods of the present disclosure can be employed to form anemissive display panel. An emissive display panel is a direct viewdisplay where the viewer directly views an image made by different colorlight emission from different color light emitting subpixels. Thesubpixels can be inorganic light emitting devices, such as lightemitting diodes. Thus, the direct view display differs from a backlightof a liquid crystal display (LCD), where different color light from thebacklight is combined to form which light which is used to illuminatethe liquid crystal material and color filters of the LCD, and the viewerviews different color light transmitted through the color filters andthe liquid crystal material. Elements on the backplane 401 and the lightemitting devices can facilitate the assembly of the display panel. Theemissive display panel may include sensors or other electronic elementsassembled onto the display panel in a similar method. Elements of thesensors and/or electronic elements facilitate assembly of the displaypanel.

In order to fabricate an emissive display panel with inorganic lightemitting diodes (LEDs) as the emissive element, millions of LEDs must beaffixed to a backplane substrate. The backplane 401 contains theelectronics which drive current through the individual LED subpixelssuch that light is emitted and an image is formed on the display.

In one embodiment, the display is a three color display panel, whereinwithin each pixel of the display there are three subpixels which emitred, green, and blue light. Each subpixel can be an inorganic LED. Theblue and green subpixels may be made of InGaN LEDs. The red subpixelsmay be made of InGaN or AlInGaP or AlGaAs LEDs. The display panel mayhave more colors. For example, a four-color display can include foursubpixels per pixel. The subpixels may emit blue light at about 470 nmwavelength, emerald green light at about 505 nm wavelength,yellowish-green light at about 570 nm wavelength, and red light at about610 nm wavelength. In one embodiment, the subpixels may all be formed ofInGaN.

The light emitting devices forming the subpixels may comprise an arrayof nanowires such that each nanowire is a light emitting device.Nanowire light emitting diodes (LEDs) are advantageous for forming thesubpixels for several reasons. First, the nanowire LEDs may be as smallas 1 micron in lateral dimension. This minimizes the amount of LEDmaterial that must be used to form each subpixel. This also allows thesubpixels to be placed at small pitches, forming a high resolutiondisplay. Second, the nanowire LEDs have excellent efficacy (lumens perwatt of electrical input power) when driven with small powers.

Referring to FIG. 26, another alternate embodiment of the structure ofthe present disclosure is shown. In addition to have a stepped backplane401 having stepped horizontal surfaces, stepped light emitting devicesurfaces can be employed to form a light emitting device assembly. Inone embodiment, stepped light emitting device surfaces can be providedthrough use of different thicknesses of, or partial absence of,solderable metallization structures on the side of each light emittingdevice (10B, 10G, 10R) or each sensor structure 10S that is bonded tothe backplane 401. In one embodiment, the solderable metallizationstructures can be a set of differential thickness contact pads (15, 16),which includes at least a first contact pad 15 having a first thicknessand a second contact pad 16 having a second thickness that is differentfrom the first thickness. Each combination of the first thickness andthe second thickness can be selected to enable use of conductive bondingstructures (430B, 430G, 430R, 430S) of the same thickness for each typeof bonded components (10B, 10G, 10R, 10S). The solderable metallizationstructures such as the set of differential thickness contact pads (15,16) can be formed, for example, by electroplating prior to dicing theinitial growth substrates (100B, 100G, 100R, 100S). One or more than onetype of bonded components (10B, 10G, 10R, 10S) can have differentialthickness contact pads (15, 16). Alternately, one or more than one typeof bonded components (10B, 10G, 10R, 10S) can have uniform thicknesscontact pads (15, 16) that have the same thickness.

Various types of devices can be bonded to the backplane 401. Forexample, in addition to, or in lieu of, bonding a set of sensor devices10S, a probe or other electronic processor integrated chips (ICs) may bebonded to the backplane 401. A non-limiting illustrative example of aprobe is a high-power infrared light emitting diode (IR LED) or avertical-cavity surface-emitting laser (VCSEL) that is used incombination with a detector to provide the functionality of gesturerecognition. A non-limiting illustrative example of an electronic IC isa low-density high cost processor chip for which direct fabrication onan active backplane is not economical, and transfer from a growthsubstrate to a backplane is more economical.

Multiple sensors, probes, and/or electronic ICs can be integrated ontothe backplane 401 employing multiple bonding steps. In one embodiment, aplurality of vertical-cavity surface-emitting lasers (VCSELs) can beemployed to form a projection display.

Tests and rework processes can be performed as needed at any stage ofthe assembly process of the present disclosure prior to formation of thetransparent encapsulation dielectric layer 470. A rework process cancomprise high-speed pick and place operations, in which a knowndefective electronic component (10G, 10G, 10R, 10S) that is bonded tothe backplane 401 can be selectively picked (for example, employinglocal heating of the respective conductive bonding structures) and afunctional replacement electronic component (10G, 10G, 10R, 10S) isplaced in its stead. A suitable clean and placement of a new set ofconductive bonding structures can be performed prior to bonding thefunctional replacement electronic component. If the rework process isperformed at a later stage, the replacement electronic components canhave a greater height than existing electronic components on thebackplane 401 (for example, by adding a thicker bonding material layeror manufacturing the electronic component with a greater height), or aplacement method that does not interfere with neighboring electroniccomponents can be employed.

In one embodiment, the conductive bonding structures (430B, 430G, 430R,430S) of the present disclosure can be solder material portions, i.e.,solder “balls.” It is understood that a solder “ball” may, or may not,have a spherical shape, and other shapes, such as a cylindrical shape,can also be employed as a solder “ball.” Referring to FIG. 27, theprocessing sequences of the present disclosure may be modified toenhance to coplanarity of the top surfaces of bonded devices from abackplane 401. After each round of bonding devices (10B, 10G, 10R, or10S) to a backplane 401 and removing a remainder of a transfer assembly,for example, after the processing steps of FIG. 14, after the processingsteps of FIG. 17, after the processing steps of FIG. 19, and/or afterthe processing steps of FIG. 21, a dummy substrate 700 having a planarbottom surface can be disposed on the top surfaces of the newly bondeddevices (10B, 10G, 10R, or 10S) and over the backplane 401.

FIG. 27 illustrates an exemplary structure after a dummy substrate 701having a planar bottom surface is disposed on top surfaces of the firstlight emitting devices 10B after separating the assembly comprising thefirst transfer substrate 301B and the second subset of the first lightemitting devices 10B from the backplane 401. The same method may beapplied after separating any of the transfer substrates (301B, 301G,301R, 301S). The dummy substrate 701 may be repeatedly used, or may bereplaced with a new one for each usage. The dummy substrate 701 cancomprise an insulator material, a conductive material, a semiconductormaterial, or a combination thereof provided that the bottom surface ofthe dummy substrate 701 includes a flat rigid surface, i.e., a surfacethat substantially coincides with a horizontal Euclidean two-dimensionalplane.

Referring to FIG. 28, a downward pressure can be applied to the dummysubstrate 700 while the conductive bonding structures (430B, 430G, 430R,430S), i.e., the solder balls, are heated to a reflow temperature.During this processing step, the dummy substrate 700 presses the newlybonded devices (10B, 10G, 10R, or 10S) toward the backplane 401. In someembodiment, the dummy substrate 700 can be used during a last reflowstep to press down on the top surfaces of the transferred devices (10B,10G, 10R, and 10S) to ensure that the top surfaces of all thetransferred dies are positioned in the same horizontal plane. In someother embodiments, previously bonded devices may not affect subsequenttransfers by careful selection of the heights of top surfaces of thepreviously bonded devices (e.g., by selecting the heights of the steppedsurfaces of the bond pads 420 and the heights of the conductive bondingstructures 430 for multiple backplanes 401 such that top surfaces oflater bonded devices are farther away from each backplane 401 thanpreviously bonded devices). FIG. 28 illustrates the step of reflowingthe first conductive bonding structures 430B while the dummy substrate700 presses the transferred first light emitting devices 10B toward thebackplane 410.

Referring to FIG. 29, subsequent processing steps can be performed toencapsulate the bonded devices (10B, 10G, 10R, 10S) employing any of theembodiments described above. The conductive bonding structures (430B,430G, 430R, 430S) can include features that are characteristic ofreflowed solder material portions such as convex reflowed surfaces.

Multiple transfer assemblies and multiple backplanes can be employed totransfer devices of different types to each backplane, and to form aperiodic array of a device set on each backplane. The devices in eachtransfer assembly can have the same two-dimensional periodicity prior toa series of device transfers. The periodic array of a device set can bethe same across the backplanes, and can have a two-dimensionalperiodicity that is multiples of the two-dimensional periodicity of thedevices on the transfer assemblies.

Referring to FIG. 30, an exemplary transfer pattern and an exemplarytransfer sequence are illustrated for transferring four different typesof devices (10B, 10G, 10R, 10S) (e.g., blue, green and red emitting LEDsand sensors, respectively) to four backplanes (BP1, BP2, BP3, BP4). Thefour different types of devices (10B, 10G, 10R, 10S) can be provided onfour source substrates (B, G, R, S), which can comprise four transfersubstrates (301B, 301G, 301R, 301S), or four growth substrates(100/500A, 100/500B, 100/500C, 100/500D), or combinations thereof. Thefirst light emitting diodes 10B can be provided on the first sourcesubstrate B, the second light emitting diodes 10G can be provided on thesecond source substrate G, the third light emitting diodes 10R can beprovided on the third source substrate R, and the sensor devices 10S canbe provided on the fourth source substrate S.

A subset of first devices 10B labeled “1” can be transferred from thefirst source substrate B to locations on the first backplane BP1 thatare marked with “1.” Subsequently, a subset of second devices 10Glabeled “2” can be transferred from the second source substrate G to asecond substrate BP2 to locations on the second backplane BP2 that aremarked with “2.” The sequential transfer continues with each set ofdevices labeled with gradually increasing numerical indices up to theset of devices labeled with the numerical index “16.”

Changes in the presence or absence of the various devices (10B, 10G,10R, 10S) on the source substrates (B, G, R, S) and the backplanes (BP1,BP2, BP3, BP4) at each step of the transfer sequence are illustrated inFIGS. 31A-31E. FIG. 31A corresponds to a configuration prior to anytransfer of the devices (10B, 10G, 10R, 10S), FIG. 31B corresponds tothe configuration after performing transfer steps 1-4, FIG. 31Ccorresponds to the configuration after performing steps 5-8, FIG. 31Dcorresponds to the configuration after performing steps 9-12, and FIG.31E corresponds to the configuration after performing steps 13-16. Itshould be noted that steps 1-4 as illustrated in FIG. 31B may beshuffled in any order because steps 1-4 are independent of one another,steps 5-8 as illustrated in FIG. 31C may be shuffled in any orderbecause steps 5-8 are independent of one another, steps 9-12 asillustrated in FIG. 31D may be shuffled in any order because steps 9-12are independent of one another, and steps 13-16 as illustrated in FIG.31E may be shuffled in any order because steps 13-16 are independent ofone another.

While the exemplary transfer pattern and the exemplary transfer sequenceis illustrated for cases in which four source substrates (B, G, R, S)and four backplanes (BP1, BP2, BP3, BP4) are employed, the method of thepresent disclosure can be applied to any case in which m transferassemblies and n backplanes are employed, in which m is an integergreater than 1, n is an integer greater than 1, and n is not less thanm. The n backplanes bond with devices from the m transfer assemblies toform n integrated light emitting device assemblies. In one embodiment, ncan be the same as, or greater than, m.

A plurality of transfer assemblies, e.g., m transfer assemblies, isprovided. Each of the m transfer assemblies comprises a respectivesource substrate (B, G, R, S) and respective devices (10B, 10G, 10R,10S) within a two-dimensional array having a same two-dimensionalperiodicity. As used herein, a same two-dimensional periodicity formultiple structures refers to a configuration in which each of themultiple structures has a respective unit structure and instances of therespective unit structure are repeated along two independent directionsof periodicity (e.g., a first periodicity direction and a secondperiodicity direction), and the unit structures are repeated along therespective first periodicity direction with a same first pitch and arerepeated along the respective second periodicity direction with a samesecond pitch for all of the multiple structures, and the angle betweenthe first periodicity direction and the second periodicity direction isthe same for all of the multiple structures. Each of the n backplaneshas a periodic repetition of respective unit conductive bondingstructures pattern configured to mount m types of devices.

Each of them types of devices can be one of the devices within arespective transfer assembly among the m transfer assemblies. Thepitches of each unit conductive bonding structures pattern along twoindependent directions within each of the n backplanes can be multiplesof a respective pitch of the two-dimensional periodicity of the deviceswithin each of the m transfer assemblies. In an illustrative example,each of the devices (10B, 10G, 10R, 10S) can be periodic within arespective transfer assembly with the first periodicity of a along afirst direction, and with the second periodicity of b along a seconddirection (which may be perpendicular to the first direction). The unitconductive bond pad pattern within each of the backplanes can have thefirst periodicity of 2 a (which is an integer multiple of a) along afirst direction, and with the second periodicity of 2 b (which is aninteger multiple of b) along a second direction (which may beperpendicular to the first direction).

Subsets of devices (10B, 10G, 10R, 10S) from each of the m transferassemblies can be sequentially transferred to a respective backplane(BP1, BP2, BP3, BP4) among the n backplanes by disposing each respectivetransfer assembly over the respective backplane (BP1, BP2, BP3, BP4) atlocations that preclude collision of existing devices on the respectivetransfer assembly with any devices (10B, 10G, 10R, 10S), if any, thatare previously bonded to the respective backplane (BP1, BP2, BP3, BP4).

Referring to FIG. 32A, an in-process structure is illustrated, which canbe employed to form a second exemplary light emitting device assemblyaccording to an embodiment of the present disclosure in which differentheight bond pads are used. As used herein, a “prototype” structure or an“in-process” structure refers to a transient structure that issubsequently modified in the shape or composition of at least onecomponent therein. The in-process structure for the second exemplarylight emitting device assembly can include a backplane substrate 400including metal interconnect structures 440 therein. The first lightemitting diodes 10B can be attached to the source substrate 301B via anablation material layer 130, which can be a release layer 20 describedabove or a portion of a source substrate 530 described above. In thisembodiment, the backplane substrate 400 may have a substantially planar(i.e., not stepped) upper surface or a stepped upper surface asillustrated in FIG. 9.

Bond pads (421, 422, 423) can be formed at locations at which variousdevices are to be subsequently bonded. The various devices can includefirst light emitting devices 10B, second light emitting devices 10G,third light emitting devices 10R, and/or sensor devices 10S describedabove. The various devices (10B, 10G, 10R, 10S) can be provided onsource substrates (B, G, R, S; Refer to FIG. 30), which can be transfersubstrates (301B, 301G, 301R, 301S), growth substrates (100/500B,100/500G, 100/500R, 100/500S), or combinations thereof. The backplane401 includes the backplane substrate 400 and the bond pads (421, 422,423).

The bond pads (421, 422, 423) can have the same composition as the bondpads 420 described above. The bond pads (421, 422, 423) can includemultiple types having different thicknesses. For example, the bond pads(421, 422, 423) can include first bond pads 421 having a firstthickness, second bond pads 422 having a second thickness, and thirdbond pads 423 having a third thickness. Additional bond pads (not shown)having different thicknesses can also be employed. In one embodiment,the first thickness can be greater than the second thickness, and thesecond thickness can be greater than the third thickness. The differencebetween the first thickness and the second thickness can be in a rangefrom 0.3 micron to 10 microns (for example, from 1 micron to 5 microns),and the difference between the second thickness and the third thicknesscan be in a range from 0.3 micron to 10 microns (for example, from 1micron to 5 microns). The thickness of the thinnest bond pads can be ina range from 1 micron to 20 microns (for example, from 2 microns to 10microns), although lesser and greater thicknesses can also be employed.

In one embodiment, conductive bonding structures (431, 432, 433) can beformed on the devices to be transferred to the backplane 401. Forexample, first light emitting diodes 10B can be the first devices to betransferred to the backplane substrate 400. The first light emittingdiodes 10B can be located on first source substrate 301B, which can be afirst transfer substrate 300B or a first-type growth substrate 100B or500B. The conductive bonding structures (431, 432, 433) can be any ofthe conductive bonding structures 430 discussed above. The conductivebonding structures (431, 432, 432) can include first conductive bondingstructures 431 formed on a first subset of the first light emittingdiodes 10B to be subsequently transferred to the backplane substrate400, second conductive bonding structures 432 formed on a second subsetof the first light emitting diodes 10B to be subsequently transferred toanother backplane substrate (not shown), third conductive bondingstructures 433 formed on a third subset of the first light emittingdiodes 10B to be subsequently transferred to yet another backplanesubstrate, and optional additional conductive bonding structures formedon another subset of the first light emitting diodes 10B to besubsequently transferred to still another backplane substrate. Theconductive bonding structures (431, 432, 433) can be formedsimultaneously on the first light emitting diodes 10B.

Alternatively, conductive bonding structures (431, 432, 433) can beformed on the bond pads (421, 422, 423) of the backplane 401. In thiscase, the conductive bonding structures (431, 432, 433) can be formedsimultaneously on all the bond pads (421, 422, 423).

Yet alternatively, each conductive bonding structure (431, 432, 433) canbe formed as two physically disjoined portions such that one portion ofeach conductive bonding structure (431, 432, or 433) is formed on afirst light emitting diode 10B and another portion of the correspondingconductive bonding structure (431, 432, or 433) is formed on a surfaceof a matching bond pad (421, 422, or 423). In one embodiment, eachconductive bonding structure (431, 432, 433) can be formed as twodisjoined portions that are divided approximately evenly between anupper portion formed on a first light emitting diode 10B and a lowerportion formed on a bond pad (421, 422, or 423).

In one embodiment, each of the conductive bonding structures (431, 432,432) can have the same height (or total height if formed in twoportions). In one embodiment, each of the conductive bonding structures(431, 432, 432) can have the same height and the same volume (or totalvolume if formed in two portions). In one embodiment, each of theconductive bonding structures (431, 432, 432) can have the same height,the same volume, and the same shape (or same sets of two shapes ifformed in two portions). The height of the conductive bonding structures(431, 432, 432) can be in a range from 15 microns to 100 microns (suchas from 20 microns to 60 microns), although lesser and greater heightscan also be employed. In one embodiment, the conductive bondingstructures (431, 432, 432) can be substantially spherical, substantiallyellipsoidal, or substantially cylindrical. The maximum horizontaldimension (such as the diameter of a spherical shape or a cylindricalshape) of each conductive bonding structures (431, 432, 433) can be in arange from 15 microns to 100 microns (such as from 20 microns to 60microns), although lesser and greater maximum horizontal dimensions canalso be employed.

Referring to FIG. 32B, the backplane 401 and the assembly including thefirst light emitting diodes 10B are positioned such that each firstconductive bonding structure 431 is attached to one of a first lightemitting device 10B and a first bonding pad 421, and contacts the otherof the first light emitting device 10B and the first bonding pad 421.Due to the difference in the thickness of the various types of bondingpads (421, 422, 423), the second conductive bonding structures 432 andthe third conductive bonding structures 433 do not contact anyunderlying bonding pads (422, 423) (in case the second conductivebonding structures 432 and the third conductive bonding structures 433are attached to the first light emitting devices 10B) or do not contactoverlying first light emitting devices 10B (in case the secondconductive bonding structures 432 and the third conductive bondingstructures 433 are attached to the second bonding pads 422 or the thirdbonding pads 423).

A reflow process is subsequently performed. The ambient temperature canbe raised to a reflow temperature of the material of the conductivebonding structures (431, 432, 432). Only the first conductive bondingstructures 431 form additional bonding with the underlying first bondingpads 421 (if the first conductive bonding structures 431 are alreadybonded to the first light emitting devices 10B) or with the overlyingfirst light emitting devices 10B (if the first conductive bondingstructures 431 are already bonded to the first bonding pads 421). Thus,each first conductive bonding structure 431 becomes bonded to theoverlying first light emitting device 10B and to the underlying firstbonding pad 421, while additional bonding is not formed for the secondand third conductive bonding structures (432, 433) during the reflowprocess. While the present disclosure is described employing anembodiment in which the backplane 401 and the assembly including thefirst light emitting diodes 10B are brought into contact with each otherprior to the reflow process, embodiments are expressly contemplatedherein in which the mechanical movement of the backplane 401 and theassembly including the first light emitting diodes 10B is performedsimultaneously with the reflow process, e.g., during temperature rampingsteps of the reflow process. While the first bonding pads 421 aredescribed above as “underlying” while the first light emitting devicesare described as “overlying” for convenience of illustration, it shouldbe understood that the components can be arranged upside down (i.e.,where first bonding pads 421 are “underlying” and the first lightemitting devices are “underlying”) or in any other position during theprocess.

Referring to FIG. 32C, a laser irradiation process is performed toseparate each bonded first light emitting device 10B from the firstsource substrate. The same laser irradiation process can be employed asdescribed above. Portions of the ablation material layer 130 overlyingthe first subset of the first light emitting diodes 10B (which arebonded to the backplane 401) are irradiated by a laser beam, and areablated. The laser ablation can be performed sequentially for each firstlight emitting diode 10B within the first subset.

Referring to FIG. 32D, the assembly of the first source substrate 301Band attached first light emitting diodes 10B (i.e., the complement ofthe first subset of the first light emitting diodes 10B) is separatedfrom the backplane 401 and the first subset of the first light emittingdiodes 10B. The first subset of the first light emitting diodes 10B isattached to the backplane 401 through the first conductive bondingstructures 431 to form the in-process second exemplary light emittingdevice assembly.

Referring to FIG. 32E, any suitable pressure plate, such as a dummysubstrate 700 is employed to push the first light emitting diodes 10B onthe first conductive bonding structures 431 toward the backplane 401.The temperature of the in-process second light emitting device assemblyis raised to the reflow temperature of the first conductive bondingstructures 431 to induce reflow of the first conductive bondingstructures 431 as the dummy substrate 700 pushes the first lightemitting diodes 10B toward the backplane 401. The push distance isselected such that the vertical distance between the bottom surfaces ofthe first bonding pads 421 and the top surfaces of the first lightemitting diodes 10B is less than the sum of the thicknesses of thethinnest bonding pads (e.g., the third bonding pads 421), the height ofthe conductive bonding structures (431, 432, 433) (which is the sameamong the conductive bonding structures), and the least height of thedevices (10G, 10R) to be subsequently attached (if the heights aredifferent) or the common height of the devices (10G, 10R) to besubsequently attached (if the heights are the same).

The processing steps of FIGS. 32A-32E can correspond to step 1illustrated in FIG. 31B, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31B. Equivalent processing steps (corresponding tostep 2 illustrated in FIG. 31B) can be performed to transfer a firstsubset of second light emitting devices 10G from a second sourcesubstrate G (which can be a second transfer substrate 300G or asecond-type growth substrate 100/500G) to first bonding pads 421 of thesecond backplane BP2 employing the transfer pattern shown in FIG. 31B(or any other pattern). Such processing steps can provide a secondsource substrate G from which a first subset of second light emittingdevices 10G are removed in a pattern that is congruent to the pattern ofthe first light emitting diodes 10B on the backplane 401.

Referring to FIG. 32F, a second source substrate (such as a secondtransfer substrate 301G) from which a first subset of second lightemitting devices 10G are removed is positioned over the in-processsecond exemplary light emitting device assembly, and is aligned suchthat a second subset of the second light emitting diodes 10G overliesthe second bonding pads 422.

Referring to FIG. 32G, the backplane 401 and the assembly including thesecond light emitting diodes 10G are positioned such that each secondconductive bonding structure 432 is attached to one of a second lightemitting device 10G and a second bonding pad 422, and contacts the otherof the second light emitting device 10G and the second bonding pad 422.Due to the difference in the thickness of the second and third bondingpads (422, 423), the third conductive bonding structures 433 do notcontact any underlying bonding pads 423 (in case the second conductivebonding structures 432 and the third conductive bonding structures 433are attached to the second light emitting devices 10G) or do not contactoverlying second light emitting devices 10G (in case the secondconductive bonding structures 432 and the third conductive bondingstructures 433 are attached to the second bonding pads 422 or the thirdbonding pads 423).

A reflow process is subsequently performed. The ambient temperature canbe raised to a reflow temperature of the material of the conductivebonding structures (431, 432, 432). The second conductive bondingstructures 432 form additional bonding with the underlying secondbonding pads 422 (if the second conductive bonding structures 432 arealready bonded to the second light emitting devices 10G) or with theoverlying second light emitting devices 10G (if the second conductivebonding structures 432 are already bonded to the second bonding pads422). Thus, each second conductive bonding structure 432 becomes bondedto the overlying second light emitting device 10G, and to the underlyingsecond bonding pad 422, while additional bonding is not formed for thethird conductive bonding structures 433 during the reflow process.

Referring to FIG. 32H, a laser irradiation process is performed toseparate each bonded second light emitting device 10G from the secondsource substrate. Portions of the ablation material layer 130 overlyingthe bonded subset (i.e., the second subset) of the second light emittingdiodes 10G (which are bonded to the backplane 401) are irradiated by alaser beam, and are ablated. The laser ablation can be performedsequentially for each second light emitting diode 10G within the subsetof the second light emitting diodes 10G that are bonded to the backplane401.

Referring to FIG. 32I, the assembly of the second source substrate 301Gand attached second light emitting diodes 10G (a third subset of thesecond light emitting diodes 10G that remain on the second sourcesubstrate) is separated from the backplane 401 and the second subset ofthe second light emitting diodes 10G that are now attached to thebackplane 401. The second subset of the second light emitting diodes 10Gis attached to the backplane 401 through the second conductive bondingstructures 432 to form the in-process second exemplary light emittingdevice assembly.

Referring to FIG. 32J, a dummy substrate 700 is employed to push thesecond light emitting diodes 10G on the second conductive bondingstructures 432 toward the backplane 401. The temperature of thein-process second light emitting device assembly is raised to the reflowtemperature of the second conductive bonding structures 432 to inducereflow of the second conductive bonding structures 432 as the dummysubstrate 700 pushes the second light emitting diodes 10G toward thebackplane 401. The push distance is selected such that the verticaldistance between the bottom surfaces of the second bonding pads 422 andthe top surfaces of the second light emitting diodes 10G is less thanthe sum of the thicknesses of the thinnest bonding pads (e.g., the thirdbonding pads 423), the height of the conductive bonding structures (431,432, 433) as originally provided (which is the same among the conductivebonding structures), and the least height of the devices (10R andoptionally 10S) to be subsequently attached (if the heights aredifferent) or the common height of the devices (10R and optionally 10S)to be subsequently attached (if the heights are the same).

The processing steps of FIGS. 32F-32J can correspond to step 6illustrated in FIG. 31C, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31C. Processing steps corresponding to step 3 inFIG. 31B and step 7 in FIG. 31C can be performed to transfer a firstsubset and a second subset of third light emitting devices 10R from athird source substrate R (which can be a third transfer substrate 300Ror a third-type growth substrate 100/500R) to bonding pads of additionalbackplanes (e.g., BP3 in FIG. 31B and BP4 in FIG. 31C) employing thetransfer pattern shown in FIGS. 31B and 31C (or any other pattern). Suchprocessing steps can provide a third source substrate R from which afirst subset and a second subset of third light emitting devices 10R areremoved in a pattern that is congruent to the combined pattern of thefirst light emitting diodes 10B and the second light emitting diodes 10Gon the backplane 401.

Referring to FIG. 32K, a third source substrate (such as a thirdtransfer substrate 301R), from which a first subset and a second subsetof third light emitting devices 10R have been removed in priorprocessing steps, is positioned over the in-process second exemplarylight emitting device assembly, and is aligned such that a third subsetof the third light emitting diodes 10R overlies the third bonding pads423.

Referring to FIG. 32L, the backplane 401 and the assembly including thethird light emitting diodes 10R are positioned such that each thirdconductive bonding structure 433 is attached to one of a third lightemitting device 10R and a third bonding pad 423, and contacts the otherof the third light emitting device 10R and the third bonding pad 423. Ifany addition bonding pads (not shown) having a lesser thickness arepresent, additional conductive bonding structures (not shown) overlyingsuch additional bonding pads do not contact any underlying additionalbonding pads (in case the additional conductive bonding structures areattached to the third source substrate) or do not contact overlyingthird light emitting devices 10R (in case the additional conductivebonding structures are attached to the additional bonding pads).

A reflow process is subsequently performed. The ambient temperature canbe raised to a reflow temperature of the material of the conductivebonding structures (431, 432, 432). The third conductive bondingstructures 433 form additional bonding with the underlying third bondingpads 423 (if the third conductive bonding structures 433 are alreadybonded to the third light emitting devices 10R) or with the overlyingthird light emitting devices 10R (if the third conductive bondingstructures 433 are already bonded to the third bonding pads 423). Thus,each third conductive bonding structure 433 becomes bonded to theoverlying third light emitting device 10R, and to the underlying thirdbonding pad 423, while additional bonding is not formed for theadditional conductive bonding structures (if present) during the reflowprocess.

Referring to FIG. 32M, a laser irradiation process is performed toseparate each bonded third light emitting device 10R from the thirdsource substrate. Portions of the ablation material layer 130 overlyingthe bonded subset (i.e., the third subset) of the third light emittingdiodes 10R (which are bonded to the backplane 401) are irradiated by alaser beam, and are ablated. The laser ablation can be performedsequentially for each third light emitting diode 10R within the subsetof the third light emitting diodes 10R that are bonded to the backplane401.

Referring to FIG. 32N, the assembly of the third source substrate 301Rand any remaining third light emitting diodes 10R, if any, is separatedfrom the backplane 401 and the third subset of the third light emittingdiodes 10R that are now attached to the backplane 401. The third subsetof the third light emitting diodes 10R is attached to the backplane 401through the third conductive bonding structures 433 to form the secondexemplary light emitting device assembly.

Optionally, a dummy substrate 700 may be employed to push the thirdlight emitting diodes 10R on the third conductive bonding structures 433toward the backplane 401. The temperature of the second light emittingdevice assembly is raised to the reflow temperature of the thirdconductive bonding structures 433 to induce reflow of the thirdconductive bonding structures 433 as the dummy substrate 700 pushes thethird light emitting diodes 10R toward the backplane 401. If anyadditional devices (such as sensor devices 10S) are to be subsequentlyattached to the backplane 401, the push distance can be selected suchthat the vertical distance between the bottom surfaces of the thirdbonding pads 423 and the top surfaces of the third light emitting diodes10R is less than the sum of the thicknesses of the additional bondingpads, the height of the additional conductive bonding structures (whichcan be the same as the height of the other conductive bonding pads (431,432, 433) as originally provided), and the least height of the devices(such as sensor devices 10S) to be subsequently.

Referring to FIG. 33A, an in-process structure is illustrated, which canbe employed to form a third exemplary light emitting device assemblyaccording to an embodiment of the present disclosure. The in-processthird exemplary light emitting device assembly can be derived from thein-process second exemplary light emitting device assembly of FIG. 32Aby employing the same thickness for the bonding pads (421, 422, 423) anddifferent heights for the conductive bonding structures (431, 432, 433).The bond pads (421, 422, 423) can have the same composition as the bondpads 420 described above. In this embodiment, the backplane substrate400 may have a substantially planar (i.e., not stepped) upper surface ora stepped upper surface as illustrated in FIG. 9, and the bond pads(421, 422, 423) can have the same height or different heights as shownin FIG. 32A.

The conductive bonding structures (431, 432, 433) can include multipletypes having different heights. For example, the conductive bondingstructures (431, 432, 433) can include first conductive bondingstructures 431 having a first height, second conductive bondingstructures 432 having a second height, and third conductive bondingstructures 433 having a third height. Additional conductive bondingstructures (not shown) having different heights can also be employed. Inone embodiment, the first height can be greater than the second height,and the second height can be greater than the third height. Thedifference between the first height and the second height can be in arange from 0.3 micron to 10 microns (for example, from 1 micron to 5microns), and the difference between the second height and the thirdheight can be in a range from 0.3 micron to 10 microns (for example,from 1 micron to 5 microns). The height of the shortest conductivebonding structures (e.g., 433) can be in a range from 10 micron to 80microns (for example, from 15 microns to 50 microns), although lesserand greater heights can also be employed.

In one embodiment, the conductive bonding structures (431, 432, 433) canbe formed on the devices to be transferred to the backplane 401. Forexample, first light emitting diodes 10B can be the first devices to betransferred to the backplane substrate 400. The first light emittingdiodes 10B can be located on first source substrate B, which can be afirst transfer substrate 30B or a first-type growth substrate 100B. Theconductive bonding structures (431, 432, 433) can be any of theconductive bonding structures 430 discussed above. The conductivebonding structures 431 are formed on a first subset of the first lightemitting diodes 10B to be subsequently transferred to the backplanesubstrate 400. The second conductive bonding structures 432 are formedon a second subset of the first light emitting diodes 10B to besubsequently transferred to another backplane substrate (not shown). Thethird conductive bonding structures 433 are formed on a third subset ofthe first light emitting diodes 10B to be subsequently transferred toyet another backplane substrate. Optionally, additional conductivebonding structures can be formed on another subset of the first lightemitting diodes 10B to be subsequently transferred to still anotherbackplane substrate.

Alternatively, conductive bonding structures (431, 432, 433) can beformed on the bond pads (421, 422, 423) of the backplane 401. In thiscase, the conductive bonding structures (431, 432, 433) can be formedsimultaneously on all the bond pads (421, 422, 423).

Yet alternatively, each conductive bonding structure (431, 432, 433) canbe formed as two physically disjoined portions such that one portion ofeach conductive bonding structure (431, 432, or 433) is formed on afirst light emitting diode 10B and another portion of the correspondingconductive bonding structure (431, 432, or 433) is formed on a surfaceof a matching bond pad (421, 422, or 423). In one embodiment, eachconductive bonding structure (431, 432, 433) can be formed as twodisjoined portions that are divided approximately evenly between anupper portion formed on a first light emitting diode 10B and a lowerportion formed on a bond pad (421, 422, or 423).

Different types of conductive bonding structures (431, 432, 433) can beformed sequentially on the first light emitting diodes 10B. The firstconductive bonding structures 431 can have a greater volume than thesecond conductive bonding structures 432, and the second conductivebonding structures 432 can have a greater volume than the thirdconductive bonding structures 433. In one embodiment, the conductivebonding structures (431, 432, 433) of different types can havesubstantially the same maximum lateral dimensions (e.g., the diameter ofa spherical shape or a cylindrical shape).

In one embodiment, the conductive bonding structures (431, 432, 432) canbe substantially ellipsoidal, or substantially cylindrical. The maximumhorizontal dimension (such as the diameter of a spherical shape or acylindrical shape) of each conductive bonding structures (431, 432, 433)can be in a range from 15 microns to 100 microns (such as from 20microns to 60 microns), although lesser and greater maximum horizontaldimensions can also be employed.

Referring to FIG. 33B, the backplane 401 and the assembly including thefirst light emitting diodes 10B are positioned such that each firstconductive bonding structure 431 is attached to one of a first lightemitting device 10B and a first bonding pad 421, and contacts the otherof the first light emitting device 10B and the first bonding pad 421.Due to the difference in the heights of the various types of conductivebonding structures (431, 432, 432), the second conductive bondingstructures 432 and the third conductive bonding structures 433 do notcontact any underlying bonding pads (422, 423) (in case the secondconductive bonding structures 432 and the third conductive bondingstructures 433 are attached to the first light emitting devices 10B) ordo not contact overlying first light emitting devices 10B (in case thesecond conductive bonding structures 432 and the third conductivebonding structures 433 are attached to the second bonding pads 422 orthe third bonding pads 423).

A reflow process is subsequently performed in the same manner as theprocessing steps of FIG. 32B.

Referring to FIG. 33C, a laser irradiation process is performed toseparate each bonded first light emitting device 10B from the firstsource substrate in the same manner as the processing steps of FIG. 32C.

Referring to FIG. 33D, the assembly of the first source substrate 301Band attached first light emitting diodes 10B (i.e., the complement ofthe first subset of the first light emitting diodes 10B) is separatedfrom the backplane 401 and the first subset of the first light emittingdiodes 10B.

Referring to FIG. 33E, a dummy substrate 700 is employed to push thefirst light emitting diodes 10B on the first conductive bondingstructures 431 toward the backplane 401 while reflowing the firstconductive bonding structures 431 in the same manner as the processingsteps of FIG. 32E.

The processing steps of FIGS. 33A-33E can correspond to step 1illustrated in FIG. 31B, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31B. Equivalent processing steps (corresponding tostep 2 illustrated in FIG. 31B) can be performed to transfer a firstsubset of second light emitting devices 10G from a second sourcesubstrate G (which can be a second transfer substrate 300G or asecond-type growth substrate 100/500G) to first bonding pads 421 of thesecond backplane BP2 employing the transfer pattern shown in FIG. 31B(or any other pattern). Such processing steps can provide a secondsource substrate G from which a first subset of second light emittingdevices 10G are removed in a pattern that is congruent to the pattern ofthe first light emitting diodes 10B on the backplane 401.

Referring to FIG. 33F, a second source substrate (such as a secondtransfer substrate 301G) from which a first subset of second lightemitting devices 10G are removed is positioned over the in-processfourth exemplary light emitting device assembly, and is aligned suchthat a second subset of the second light emitting diodes 10G overliesthe second bonding pads 422.

Referring to FIG. 33G, the backplane 401 and the assembly including thesecond light emitting diodes 10G are positioned such that each secondconductive bonding structure 432 is attached to one of a second lightemitting device 10G and a second bonding pad 422, and contacts the otherof the second light emitting device 10G and the second bonding pad 422.Due to the difference in the heights of the second and third conductivebonding structures (432, 433), the third conductive bonding structures433 do not contact any underlying bonding pads 423 (in case the secondconductive bonding structures 432 and the third conductive bondingstructures 433 are attached to the second light emitting devices 10G) ordo not contact overlying second light emitting devices 10G (in case thesecond conductive bonding structures 432 and the third conductivebonding structures 433 are attached to the second bonding pads 422 orthe third bonding pads 423).

A reflow process is subsequently performed in the same manner as theprocessing steps of FIG. 32G. Each second conductive bonding structure432 becomes bonded to the overlying second light emitting device 10G,and to the underlying second bonding pad 422, while additional bondingis not formed for the third conductive bonding structures 433 during thereflow process.

Referring to FIG. 33H, a laser irradiation process is performed toseparate each bonded second light emitting device 10G from the secondsource substrate. The same laser irradiation process can be performed asin the processing steps of FIG. 32H.

Referring to FIG. 33I, the assembly of the second source substrate 301Gand attached second light emitting diodes 10G (a third subset of thesecond light emitting diodes 10G that remain on the second sourcesubstrate) is separated from the backplane 401 and the second subset ofthe second light emitting diodes 10G that are now attached to thebackplane 401.

Referring to FIG. 33J, a dummy substrate 700 is employed to push thesecond light emitting diodes 10G on the second conductive bondingstructures 432 toward the backplane 401 in the same manner as in theprocessing steps of FIG. 32J.

The processing steps of FIGS. 33F-33J can correspond to step 6illustrated in FIG. 31C, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31C. Processing steps corresponding to step 3 inFIG. 31B and step 7 in FIG. 31C can be performed to transfer a firstsubset and a second subset of third light emitting devices 10R from athird source substrate R (which can be a third transfer substrate 300Ror a third-type growth substrate 100/500R) to bonding pads of additionalbackplanes (e.g., BP3 in FIG. 31B and BP4 in FIG. 31C) employing thetransfer pattern shown in FIGS. 31B and 31C (or any other pattern). Suchprocessing steps can provide a third source substrate R from which afirst subset and a second subset of third light emitting devices 10R areremoved in a pattern that is congruent to the combined pattern of thefirst light emitting diodes 10B and the second light emitting diodes 10Gon the backplane 401.

Referring to FIG. 33K, a third source substrate (such as a thirdtransfer substrate 301R), from which a first subset and a second subsetof third light emitting devices 10R have been removed in priorprocessing steps, is positioned over the in-process second exemplarylight emitting device assembly, and is aligned such that a third subsetof the third light emitting diodes 10R overlies the third bonding pads423.

Referring to FIG. 33L, the backplane 401 and the assembly including thethird light emitting diodes 10R are positioned such that each thirdconductive bonding structure 433 is attached to one of a third lightemitting device 10R and a third bonding pad 423, and contacts the otherof the third light emitting device 10R and the third bonding pad 423. Ifany addition conductive bonding structures (not shown) having a lesserheight are present, additional conductive bonding structures (not shown)overlying such additional bonding pads do not contact any underlyingadditional bonding pads (in case the additional conductive bondingstructures are attached to the third source substrate) or do not contactoverlying third light emitting devices 10R (in case the additionalconductive bonding structures are attached to the additional bondingpads).

A reflow process is subsequently performed in the same manner as in theprocessing steps of FIG. 32L.

Referring to FIG. 33M, a laser irradiation process is performed toseparate each bonded third light emitting device 10R from the thirdsource substrate in the same manner as in the processing steps of FIG.32M.

Referring to FIG. 33N, the assembly of the third source substrate 301Rand any remaining third light emitting diodes 10R, if any, is separatedfrom the backplane 401 and the third subset of the third light emittingdiodes 10R that are now attached to the backplane 401 in the same manneras in the processing steps of FIG. 32N.

Optionally, a dummy substrate 700 may be employed to push the thirdlight emitting diodes 10R on the third conductive bonding structures 433toward the backplane 401 in the same manner as in the processing stepsof FIG. 32N.

Referring to FIG. 34A, an in-process structure is illustrated, which canbe employed to form a fourth exemplary light emitting device assemblyaccording to an embodiment of the present disclosure in which selectivelaser soldering is used to bond devices to the backplane. The in-processfourth exemplary light emitting device assembly can be derived from thein-process second exemplary light emitting device assembly of FIG. 32Aor the in-process third exemplary light emitting device assembly of FIG.33A by employing the same thickness for the bonding pads (421, 422, 423)and the same height for the conductive bonding structures (431, 432,433). The bond pads (421, 422, 423) can have the same composition as thebond pads 420 described above. The conductive bonding structures (431,432, 433) can have the same composition as the conductive bondingstructures 430 described above. In this embodiment, the backplanesubstrate 400 may have a substantially planar (i.e., not stepped) uppersurface or a stepped upper surface as illustrated in FIG. 9. The bondpads (421, 422, 423) can have the same height or different heights asshown in FIG. 32A. The conductive bonding structures (431, 432, 433) canhave the same height or different heights as shown in FIG. 33A.

In one embodiment, the conductive bonding structures (431, 432, 433) canbe formed on the devices to be transferred to the backplane 401. Forexample, first light emitting diodes 10B can be the first devices to betransferred to the backplane substrate 400. The first light emittingdiodes 10B can be located on first source substrate 301B, which can be afirst transfer substrate 300B or a first-type growth substrate 100/500B.The conductive bonding structures (431, 432, 433) can be any of theconductive bonding structures 430 discussed above. The conductivebonding structures 431 are formed on a first subset of the first lightemitting diodes 10B to be subsequently transferred to the backplanesubstrate 400. The second conductive bonding structures 432 are formedon a second subset of the first light emitting diodes 10B to besubsequently transferred to another backplane substrate (not shown). Thethird conductive bonding structures 433 are formed on a third subset ofthe first light emitting diodes 10B to be subsequently transferred toyet another backplane substrate. Optionally, additional conductivebonding structures can be formed on another subset of the first lightemitting diodes 10B to be subsequently transferred to still anotherbackplane substrate.

Alternatively, conductive bonding structures (431, 432, 433) can beformed on the bond pads (421, 422, 423) of the backplane 401. In thiscase, the conductive bonding structures (431, 432, 433) can be formedsimultaneously on all the bond pads (421, 422, 423).

Yet alternatively, each conductive bonding structure (431, 432, 433) canbe formed as two physically disjoined portions such that one portion ofeach conductive bonding structure (431, 432, or 433) is formed on afirst light emitting diode 10B and another portion of the correspondingconductive bonding structure (431, 432, or 433) is formed on a surfaceof a matching bond pad (421, 422, or 423). In one embodiment, eachconductive bonding structure (431, 432, 433) can be formed as twodisjoined portions that are divided approximately evenly between anupper portion formed on a first light emitting diode 10B and a lowerportion formed on a bond pad (421, 422, or 423).

In one embodiment, the conductive bonding structures (431, 432, 432) canbe substantially spherical, substantially ellipsoidal, or substantiallycylindrical. The maximum horizontal dimension (such as the diameter of aspherical shape or a cylindrical shape) of each conductive bondingstructures (431, 432, 433) can be in a range from 15 microns to 100microns (such as from 20 microns to 60 microns), although lesser andgreater maximum horizontal dimensions can also be employed.

Referring to FIG. 34B, the backplane 401 and the assembly including thefirst light emitting diodes 10B are positioned such that each conductivebonding structure (431, 432, 433) is attached to one of a first lightemitting device 10B and a bonding pad (421, 422, or 423), and contactsthe other of the first light emitting device 10B and the bonding pad(421, 422, or 423). In one embodiment, each first conductive bondingstructure 431 can be attached to one of an overlying first lightemitting device 10B and a first bonding pad 421, and contacts the otherof the overlying first light emitting device 10B and the first bondingpad 421; each second conductive bonding structure 432 can be attached toone of an overlying first light emitting device 10B and a second bondingpad 422, and contacts the other of the overlying first light emittingdevice 10B and the second bonding pad 422; and each third conductivebonding structure 433 can be attached to one of an overlying first lightemitting device 10B and a third bonding pad 423, and contacts the otherof the overlying first light emitting device 10B and the third bondingpad 423.

A heating laser 467 can be employed to reflow the first conductivebonding structures 431. The heating laser 467 can have a wavelength thatinduces greater absorption of energy within the material of theconductive bonding structures (431, 432, 433) than within the materialsof the source substrate 301B or within the materials of the devices tobe transferred (e.g., the first light emitting devices 10B). Forexample, the heating laser 467 can have a wavelength in a range from 0.8micron to 20 microns, such as 1 to 2 microns, to provide a differentialheating between the material of the conductive bonding structures 431which are to be reflowed and the material of the conductive bondingstructures 432, 433 which are not to be reflowed. Differential heatingis also provided between the conductive bonding structures 431 and thematerials of the source substrate 301B and the devices to betransferred. The first conductive bonding structures 431 can beselectively heated by sequential irradiation of a laser beam from theheating layer 467 to reflow each first conductive bonding structure 431,and to bond each first conductive bonding structure 431 to an overlyingfirst light emitting device 10B and to an underlying first bonding pad421. Preferably, the laser beam is provided through the source substrate301B. The laser beam may be transmitted through the source substrate301B and through the devices to the conductive bonding structures 431for selective heating. Alternatively, the laser beam may be absorbed bythe source substrate or the device adjacent to the conductive bondingstructures 431 to selectively heat and reflow the conductive bondingstructures 431 without reflowing the remaining conductive bondingstructures (432, 433).

Referring to FIG. 34C, a laser irradiation process is performed toseparate each bonded first light emitting device 10B from the firstsource substrate in the same manner as the processing steps of FIG. 32C.The wavelength of the laser 477 (which is herein referred to an“ablation laser”) can be different (e.g., shorter) from the wavelengthof the heating laser 467, for example between 0.1 and 0.75 micron, suchas 0.25 to 0.5 micron. The laser provides more heating to the materialof the ablation material layer 130 than to the materials of the sourcesubstrate 301B and the transferred devices (e.g., the first lightemitting diodes 10B). Each portion of the ablation material layer 130overlying the first conductive bonding structures 431 can besequentially irradiated by a laser beam from the laser 477 to dissociateeach underlying first light emitting device 10B.

Referring to FIG. 34D, the assembly of the first source substrate 301Band attached first light emitting diodes 10B (i.e., the complement ofthe first subset of the first light emitting diodes 10B) is separatedfrom the backplane 401 and the first subset of the first light emittingdiodes 10B.

Referring to FIG. 34E, a dummy substrate 700 is employed to push thefirst light emitting diodes 10B on the first conductive bondingstructures 431 toward the backplane 401 while reflowing the firstconductive bonding structures 431 in the same manner as the processingsteps of FIG. 32E.

The processing steps of FIGS. 34A-34E can correspond to step 1illustrated in FIG. 31B, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31B. Equivalent processing steps (corresponding tostep 2 illustrated in FIG. 31B) can be performed to transfer a firstsubset of second light emitting devices 10G from a second sourcesubstrate G (which can be a second transfer substrate 300G or asecond-type growth substrate 100/500G) to first bonding pads 421 of thesecond backplane BP2 employing the transfer pattern shown in FIG. 31B(or any other pattern). Such processing steps can provide a secondsource substrate G from which a first subset of second light emittingdevices 10G are removed in a pattern that is congruent to the pattern ofthe first light emitting diodes 10B on the backplane 401.

Referring to FIG. 34F, a second source substrate (such as a secondtransfer substrate 301G) from which a first subset of second lightemitting devices 10G are removed is positioned over the in-processfourth exemplary light emitting device assembly, and is aligned suchthat a second subset of the second light emitting diodes 10G overliesthe second bonding pads 422.

Referring to FIG. 34G, the backplane 401 and the assembly including thesecond light emitting diodes 10G are positioned such that each secondconductive bonding structure 432 is attached to one of a second lightemitting device 10G and a second bonding pad 422, and contacts the otherof the second light emitting device 10G and the second bonding pad 422.

In one embodiment, each second conductive bonding structure 432 can beattached to one of an overlying second light emitting device 10G and asecond bonding pad 422, and contacts the other of the overlying secondlight emitting device 10G and the second bonding pad 422; and each thirdconductive bonding structure 433 can be attached to one of an overlyingsecond light emitting device 10G and a third bonding pad 423, andcontacts the other of the overlying second light emitting device 10G andthe third bonding pad 423.

A heating laser 467 is employed to reflow the second conductive bondingstructures 432 without reflowing the remaining conductive bondingstructures (431, 433). The heating laser 467 can have a wavelength thatinduces greater absorption of energy within the material of theconductive bonding structures (431, 432, 433) than within the materialsof the source substrate 301G or within the materials of the devices tobe transferred (e.g., the second light emitting devices 10G). The sameheating laser can be employed as in the processing steps of FIG. 34B.The second conductive bonding structures 432 can be sequentiallyirradiated by a laser beam from the heating layer 467 to reflow eachsecond conductive bonding structure 432, and to bond each secondconductive bonding structure 432 to an overlying second light emittingdevice 10G and to an underlying second bonding pad 422.

Referring to FIG. 34H, a laser irradiation process is performed toseparate each bonded second light emitting device 10G from the secondsource substrate in the same manner as the processing steps of FIG. 32H.The wavelength of the laser 477 can be different from the wavelength ofthe heating laser 467, and provides more heating to the material of theablation material layer 130 than to the materials of the sourcesubstrate 301G and the transferred devices (e.g., the second lightemitting diodes 10G). Each portion of the ablation material layer 130overlying the second conductive bonding structures 432 can besequentially irradiated by a laser beam from the layer 477 to dissociateeach underlying second light emitting device 10G.

Referring to FIG. 34I, the assembly of the second source substrate 301Gand attached second light emitting diodes 10G (a third subset of thesecond light emitting diodes 10G that remain on the second sourcesubstrate) is separated from the backplane 401 and the second subset ofthe second light emitting diodes 10G that are now attached to thebackplane 401.

Referring to FIG. 34J, a dummy substrate 700 is employed to push thesecond light emitting diodes 10G on the second conductive bondingstructures 432 toward the backplane 401 in the same manner as in theprocessing steps of FIG. 32J.

The processing steps of FIGS. 34F-34J can correspond to step 6illustrated in FIG. 31C, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31C. Processing steps corresponding to step 3 inFIG. 31B and step 7 in FIG. 31C can be performed to transfer a firstsubset and a second subset of third light emitting devices 10R from athird source substrate R (which can be a third transfer substrate 300Ror a third-type growth substrate 100/500R) to bonding pads of additionalbackplanes (e.g., BP3 in FIG. 31B and BP4 in FIG. 31C) employing thetransfer pattern shown in FIGS. 31B and 31C (or any other pattern). Suchprocessing steps can provide a third source substrate R from which afirst subset and a second subset of third light emitting devices 10R areremoved in a pattern that is congruent to the combined pattern of thefirst light emitting diodes 10B and the second light emitting diodes 10Gon the backplane 401.

Referring to FIG. 34K, a third source substrate (such as a thirdtransfer substrate 301R), from which a first subset and a second subsetof third light emitting devices 10R have been removed in priorprocessing steps, is positioned over the in-process fourth exemplarylight emitting device assembly, and is aligned such that a third subsetof the third light emitting diodes 10R overlies the third bonding pads423.

Referring to FIG. 34L, the backplane 401 and the assembly including thethird light emitting diodes 10R are positioned such that each thirdconductive bonding structure 433 is attached to one of a third lightemitting device 10R and a third bonding pad 423, and contacts the otherof the third light emitting device 10R and the third bonding pad 423. Ifany addition conductive bonding structures (not shown) are present,additional conductive bonding structures (not shown) overlying suchadditional bonding pads can contact underlying additional bonding padsand overlying third light emitting devices 10R, and can be attached tothe underlying additional bonding pads or to the overlying third lightemitting devices 10R.

A heating laser 467 is employed to reflow the third conductive bondingstructures 433. The heating laser 467 can have a wavelength that inducesgreater absorption of energy within the material of the third conductivebonding structures 433 than within the materials of the source substrate301R or within the materials of the devices to be transferred (e.g., thethird light emitting devices 10R). The same heating laser can beemployed as in the processing steps of FIG. 34B or FIG. 34G. The thirdconductive bonding structures 433 can be sequentially irradiated by alaser beam from the heating layer 467 to reflow each third conductivebonding structure 433, and to bond each third conductive bondingstructure 433 to an overlying third light emitting device 10R and to anunderlying third bonding pad 423.

Referring to FIG. 34M, a laser irradiation process is performed toseparate each bonded third light emitting device 10R from the thirdsource substrate in the same manner as in the processing steps of FIG.32M.

Referring to FIG. 34N, the assembly of the third source substrate 301Rand any remaining third light emitting diodes 10R, if any, is separatedfrom the backplane 401 and the third subset of the third light emittingdiodes 10R that are now attached to the backplane 401 in the same manneras in the processing steps of FIG. 32N.

Optionally, a dummy substrate 700 may be employed to push the thirdlight emitting diodes 10R on the third conductive bonding structures 433toward the backplane 401 in the same manner as in the processing stepsof FIG. 32N.

Referring to FIG. 35A, an in-process structure is illustrated, which canbe employed to form a fifth exemplary light emitting device assemblyaccording to an embodiment of the present disclosure in which componentsare bonded at the same time by non-selective heating rather than byselective laser heating. The in-process fifth exemplary light emittingdevice assembly can be the same as the in-process fourth exemplary lightemitting device assembly of FIG. 34A. In this embodiment, the backplanesubstrate 400 may have a substantially planar (i.e., not stepped) uppersurface or a stepped upper surface as illustrated in FIG. 9. The bondpads (421, 422, 423) can have the same height or different heights asshown in FIG. 32A. The conductive bonding structures (431, 432, 433) canhave the same height or different heights as shown in FIG. 33A.

In one embodiment, the conductive bonding structures (431, 432, 433) canbe formed on the devices to be transferred to the backplane 401. Forexample, first light emitting diodes 10B can be the first devices to betransferred to the backplane substrate 400. The first light emittingdiodes 10B can be located on first source substrate B, which can be afirst transfer substrate 300B or a first-type growth substrate 100/500B.The conductive bonding structures (431, 432, 433) can be any of theconductive bonding structures 430 discussed above.

Alternatively, conductive bonding structures (431, 432, 433) can beformed on the bond pads (421, 422, 423) of the backplane 401. In thiscase, the conductive bonding structures (431, 432, 433) can be formedsimultaneously on all the bond pads (421, 422, 423).

Yet alternatively, each conductive bonding structure (431, 432, 433) canbe formed as two physically disjoined portions such that one portion ofeach conductive bonding structure (431, 432, or 433) is formed on afirst light emitting diode 10B and another portion of the correspondingconductive bonding structure (431, 432, or 433) is formed on a surfaceof a matching bond pad (421, 422, or 423). In one embodiment, eachconductive bonding structure (431, 432, 433) can be formed as twodisjoined portions that are divided approximately evenly between anupper portion formed on a first light emitting diode 10B and a lowerportion formed on a bond pad (421, 422, or 423).

In one embodiment, the conductive bonding structures (431, 432, 432) canbe substantially spherical, substantially ellipsoidal, or substantiallycylindrical. The maximum horizontal dimension (such as the diameter of aspherical shape or a cylindrical shape) of each conductive bondingstructures (431, 432, 433) can be in a range from 15 microns to 100microns (such as from 20 microns to 60 microns), although lesser andgreater maximum horizontal dimensions can also be employed.

Referring to FIG. 35B, the backplane 401 and the assembly including thefirst light emitting diodes 10B are positioned such that each conductivebonding structure (431, 432, 433) is attached to one of a first lightemitting device 10B and a bonding pad (421, 422, or 423), and contactsthe other of the first light emitting device 10B and the bonding pad(421, 422, or 423). In one embodiment, each first conductive bondingstructure 431 can be attached to one of an overlying first lightemitting device 10B and a first bonding pad 421, and contacts the otherof the overlying first light emitting device 10B and the first bondingpad 421; each second conductive bonding structure 432 can be attached toone of an overlying first light emitting device 10B and a second bondingpad 422, and contacts the other of the overlying first light emittingdevice 10B and the second bonding pad 422; and each third conductivebonding structure 433 can be attached to one of an overlying first lightemitting device 10B and a third bonding pad 423, and contacts the otherof the overlying first light emitting device 10B and the third bondingpad 423.

A reflow process is performed to reflow the conductive bondingstructures (431, 432, 433). The reflow process can be performed byproviding uniform heating to the conductive bonding structures (431,432, 433), for example, by placing the assembly of the backplane 401 andthe first source substrate 301B with attached structures thereupon intoa furnace or any other temperature controlled environment. Eachconductive bonding structure (431, 432, 433) can be bonded to anoverlying first light emitting device 10B and an underlying bonding pad(421, 422, 423). The bonding of the conductive bonding structure (431,432, 433) can occur simultaneously.

Referring to FIG. 35C, a laser irradiation process is performed toseparate each bonded first light emitting device 10B from the firstsource substrate in the same manner as the processing steps of FIG. 32C.The wavelength of the laser 477 provides more heating to the material ofthe ablation material layer 130 than to the materials of the sourcesubstrate 301B and the transferred devices (e.g., the first lightemitting diodes 10B). Each portion of the ablation material layer 130overlying the first conductive bonding structures 431 can besequentially irradiated by a laser beam from the layer 477 to dissociateeach underlying first light emitting device 10B. In one embodiment, thetemperature of the conductive bonding structures (431, 432, 433) can bemaintained below the reflow temperature during dissociation processemploying laser irradiation. Alternatively, the temperature of theconductive bonding structures (431, 432, 433) can be maintained near thereflow temperature during dissociation process employing laserirradiation

Referring to FIG. 35D, the temperature of the conductive bondingstructures (431, 432, 433) can be changed to a preset temperature, whichis herein referred to as a “separation temperature” by non-selectiveheating, such as furnace heating. The separation temperature is atemperature at which each of the second and third conductive bondingstructures (432, 433) can be split into two portions without causingadditional fractures in the second and third bonding structures (432,433). The separation temperature may be the same as the reflowtemperature, may be lower than the reflow temperature (for example, byless than 10 degrees Celsius), or may be higher than the reflowtemperature (for example, by less than 20 degrees Celsius). In oneembodiment, the temperature of the conductive bonding structures (431,432, 433) can be at the reflow temperature at the processing steps ofFIG. 35B, be lowered to a process temperature that is lower than thereflow temperature at the processing steps of FIG. 35C, and be raised tothe separation temperature at the processing steps of FIG. 35D.

The first conductive bonding structures 431 are not attached to thefirst source substrate 301B after the laser ablation process of FIG.35C. As the assembly of the first source substrate 301B and attachedfirst light emitting diodes 10B (i.e., the complement of the firstsubset of the first light emitting diodes 10B) is pulled away from thebackplane 401 and the first subset of the first light emitting diodes10B at the separation temperature, each of the second and thirdconductive bonding structures (432, 433) can be divided into twoportions. For example, each second conductive bonding structure 432 canbe divided into an upper second conductive bonding material portion 432Uattached to a first light emitting device 10B and a lower secondconductive bonding material portion 432L attached to the backplane 401,and each third conductive bonding structure 433 can be divided into anupper third conductive bonding material portion 433U attached to a firstlight emitting device 10B and a lower third conductive bonding materialportion 433L attached to the backplane 401. The ratio of the amount ofthe conductive bonding material in an upper conductive bonding materialportion (432U or 433U) to the amount of the conductive bonding materialin an underlying lower conductive bonding material portion (432L or433L) can be about 1 or less than 1 depending on the selection of theseparation temperature.

Referring to FIG. 35E, a dummy substrate 700 is employed to push thefirst light emitting diodes 10B on the first conductive bondingstructures 431 toward the backplane 401 while reflowing the firstconductive bonding structures 431 in the same manner as the processingsteps of FIG. 32E.

The processing steps of FIGS. 35A-35E can correspond to step 1illustrated in FIG. 31B, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31B. Equivalent processing steps (corresponding tostep 2 illustrated in FIG. 31B) can be performed to transfer a firstsubset of second light emitting devices 10G from a second sourcesubstrate G (which can be a second transfer substrate 300G or asecond-type growth substrate 100/500G) to first bonding pads 421 of thesecond backplane BP2 employing the transfer pattern shown in FIG. 31B(or any other pattern). Such processing steps can provide a secondsource substrate G from which a first subset of second light emittingdevices 10G are removed in a pattern that is congruent to the pattern ofthe first light emitting diodes 10B on the backplane 401.

Referring to FIG. 35F, a second source substrate (such as a secondtransfer substrate 301G) from which a first subset of second lightemitting devices 10G are removed is positioned over the in-process fifthexemplary light emitting device assembly, and is aligned such that asecond subset of the second light emitting diodes 10G overlies thesecond bonding pads 422. Each upper conductive bonding material portion(432U or 433U) can be aligned to an underlying lower conductive bondingmaterial portion (432L or 433L) after the alignment process.

Referring to FIG. 35G, the backplane 401 and the assembly including thesecond light emitting diodes 10G are brought into contact with eachother while the temperature is raised to the reflow temperature of thematerial of the upper conductive bonding material portions (432U, 433U)and the lower conductive bonding material portions (432L, 433L). Thesimultaneous ramping up of the temperature and reduction of theseparation distance between the upper conductive bonding materialportions (432U, 433U) and the lower conductive bonding material portions(432L, 433L) can avoid breakage of, and/or misalignment between, theupper conductive bonding material portions (432U, 433U) and the lowerconductive bonding material portions (432L, 433L) due to irregularity inthe shapes thereof.

Each vertically adjoined pair of an upper second conductive bondingmaterial portion 432U and a lower second conductive bonding materialportion 432L merges to form a second conductive bonding structure 432.Each vertically adjoined pair of an upper third conductive bondingmaterial portion 433U and a lower third conductive bonding materialportion 433L merges to form a second conductive bonding structure 433.Each second conductive bonding structure 432 is bonded to an overlyingsecond light emitting device 10G and an underlying second bonding pad422. Each third conductive bonding structure 433 is bonded to anoverlying second light emitting device 10G and an underlying thirdbonding pad 423.

Referring to FIG. 35H, a laser irradiation process is performed toseparate each bonded second light emitting device 10G from the secondsource substrate in the same manner as the processing steps of FIG. 32H.The wavelength of the laser 477 provides more heating to the material ofthe ablation material layer 130 than to the materials of the sourcesubstrate 301G and the transferred devices (e.g., the second lightemitting diodes 10G). Each portion of the ablation material layer 130overlying the second conductive bonding structures 432 can besequentially irradiated by a laser beam from the layer 477 to dissociateeach underlying second light emitting device 10G.

Referring to FIG. 35I, the second conductive bonding structures 432 arenot attached to the second source substrate 301B after the laserablation process of FIG. 35C. The temperature of the conductive bondingstructures (431, 432, 433) can be changed to the separation temperature,and the assembly of the second source substrate 301G and attached secondlight emitting diodes 10G is pulled away from the backplane 401 and thefirst subset of the first light emitting diodes 10B at the separationtemperature. Each of the third conductive bonding structures 433 can bedivided into two portions. Specifically, each third conductive bondingstructure 433 can be divided into an upper third conductive bondingmaterial portion 433U attached to a first light emitting device 10B anda lower third conductive bonding material portion 433L attached to thebackplane 401. The ratio of the amount of the conductive bondingmaterial in an upper third conductive bonding material portion 433U tothe amount of the conductive bonding material in an underlying lowerthird conductive bonding material portion 433L can be about 1 or lessthan 1 depending on the selection of the separation temperature.

Referring to FIG. 35J, a dummy substrate 700 is employed to push thesecond light emitting diodes 10G on the second conductive bondingstructures 432 toward the backplane 401 in the same manner as in theprocessing steps of FIG. 32J.

The processing steps of FIGS. 35F-35J can correspond to step 6illustrated in FIG. 31C, in which the backplane 401 corresponds to thebackplane BP1 in FIG. 31C. Processing steps corresponding to step 3 inFIG. 31B and step 7 in FIG. 31C can be performed to transfer a firstsubset and a second subset of third light emitting devices 10R from athird source substrate R (which can be a third transfer substrate 300Ror a third-type growth substrate 100/500R) to bonding pads of additionalbackplanes (e.g., BP3 in FIG. 31B and BP4 in FIG. 31C) employing thetransfer pattern shown in FIGS. 31B and 31C (or any other pattern). Suchprocessing steps can provide a third source substrate R from which afirst subset and a second subset of third light emitting devices 10R areremoved in a pattern that is congruent to the combined pattern of thefirst light emitting diodes 10B and the second light emitting diodes 10Gon the backplane 401.

Referring to FIG. 35K, a third source substrate (such as a thirdtransfer substrate 301R), from which a first subset and a second subsetof third light emitting devices 10R have been removed in priorprocessing steps, is positioned over the in-process fifth exemplarylight emitting device assembly, and is aligned such that a third subsetof the third light emitting diodes 10R overlies the third bonding pads423. Each upper third conductive bonding material portion 433U can bealigned to an underlying lower third conductive bonding material portion433L after the alignment process.

Referring to FIG. 35L, the backplane 401 and the assembly including thesecond light emitting diodes 10G are brought into contact with eachother while the temperature is raised to the reflow temperature of thematerial of the upper third conductive bonding material portions 433Uand the lower third conductive bonding material portions 433L. Thesimultaneous ramping up of the temperature and reduction of theseparation distance between the upper third conductive bonding materialportions 433U and the lower third conductive bonding material portions433L can avoid breakage of, and/or misalignment between, the upper thirdconductive bonding material portions 433U and the lower third conductivebonding material portions 433L due to irregularity in the shapesthereof.

Each vertically adjoined pair of an upper third conductive bondingmaterial portion 433U and a lower third conductive bonding materialportion 433L merges to form a second conductive bonding structure 433.Each third conductive bonding structure 433 is bonded to an overlyingsecond light emitting device 10G and an underlying third bonding pad423.

Referring to FIG. 35M, a laser irradiation process is performed toseparate each bonded third light emitting device 10R from the thirdsource substrate in the same manner as in the processing steps of FIG.32M.

Referring to FIG. 35N, the assembly of the third source substrate 301Rand any remaining third light emitting diodes 10R, if any, is separatedfrom the backplane 401 and the third subset of the third light emittingdiodes 10R that are now attached to the backplane 401 in the same manneras in the processing steps of FIG. 32N.

Optionally, a dummy substrate 700 may be employed to push the thirdlight emitting diodes 10R on the third conductive bonding structures 433toward the backplane 401 in the same manner as in the processing stepsof FIG. 32N.

According to various embodiments of the present disclosure, a method offorming at least one integrated light emitting device assembly isprovided. A first assembly comprising a first source substrate 301B andfirst light emitting devices 10B that emits light of a first wavelengthis disposed over a backplane 401. First conductive bonding structures(430B or 431) are disposed between the backplane 401 and the firstassembly. A first subset of the first light emitting devices 10B isbonded to the backplane 401 through the first conductive bondingstructures (430B or 431). The first subset of the first light emittingdevices 10B is detached from the first source substrate 301B by laserablation of material portions 130 overlying the first subset of thefirst light emitting devices 10B. An assembly comprising the firstsource substrate 301B and a second subset of the first light emittingdevices 10B is separated from the backplane 401 while the first subsetof the first light emitting devices 10B remains bonded to the backplane401 as illustrated in FIGS. 14, 32D, 33D, 34D, and 35D.

In one embodiment, a second assembly comprising a second sourcesubstrate 301G and second light emitting devices 10G is provided. Thesecond light emitting devices 10G emit light of a second wavelength thatis different from the first wavelength. The second light emittingdevices 10G are not present in vacancy positions that form a firstpattern (such as the pattern or vacancy in the second source substrate Gin FIG. 31B). The second assembly comprising the second source substrate301G and the second light emitting devices 10G is disposed over thebackplane 401. Second conductive bonding structures 432 are disposedbetween the backplane 401 and the second assembly. The vacancy positionsof the first pattern overlie all areas of the first light emittingdevices 10B that are bonded to the backplane 402 when the secondassembly is disposed over the backplane 401, as illustrated in FIGS. 15,16, 32F, 32G, 33F, 33G, 34F, 34G, 35F, and 35G.

In one embodiment, a first subset of the second light emitting devices10G is bonded to the backplane 401 through the second conductive bondingstructures (430G or 432). The first subset of the second light emittingdevices 10G is detached from the second source substrate 301G by laserablation of material portions 130 overlying the first subset of thesecond light emitting devices; and 10G. An assembly comprising thesecond source substrate 301G and a second subset of the second lightemitting devices 10G is separated from the backplane 401 while the firstsubset of the second light emitting devices 10G remains bonded to thebackplane 401, as illustrated in FIGS. 17, 32I, 33I, 34I, and 35I.

In one embodiment, a third assembly comprising a third source substrate301R and third light emitting devices 10R is provided. The third lightemitting devices 10R emit light of a third wavelength that is differentfrom the first wavelength and from the second wavelength. The thirdlight emitting devices 10R are not present in vacancy positions thatform a second pattern such as the pattern of vacancy positions over thethird source substrate R in FIG. 31C. The third assembly comprising thethird source substrate 301R and the third light emitting devices 10R isdisposed over the backplane 401. Third conductive bonding structures(430R or 433) are disposed between the backplane 401 and the thirdassembly. The vacancy positions in the second pattern overlie all areasof the first and second light emitting devices (10B, 10G) that arebonded to the backplane 401 when the third assembly is disposed over thebackplane 401, as illustrated in FIGS. 18, 32K, 32L, 33K, 33L, 34K, 34L,35K, and 35L.

In one embodiment, a first subset of the third light emitting devices10R is bonded to the backplane 401 through the third conductive bondingstructures (430R or 433). The first subset of the third light emittingdevices 10R is detached from the third source substrate 301R by laserablation of material portions 130 overlying the first subset of thethird light emitting devices 10R. An assembly comprising the thirdsource substrate 301R and a second subset of the third light emittingdevices 10R is separated from the backplane 401 while the first subsetof the third light emitting devices 10R remains bonded to the backplane401 as illustrated in FIG. 19 or in processing steps immediatelyfollowing the processing steps of FIG. 32M, 33M, 34M, or 35M.

First bonding pads (420 or 421) and second bonding pads (420 or 421) areprovided on the backplane 401. The first conductive bonding structures(430B or 431) overlie the first bonding pads (420 or 421) and the secondconductive bonding structures (430G or 432) overlie the second bondingpads (420 or 422) when the first assembly is disposed over the backplane401. The first conductive bonding structures (430B or 431) are bonded tothe first subset of the first light emitting devices 10B and to thefirst bonding pads (420 or 421) when the first subset of the first lightemitting devices 10B are bonded to the backplane 401 as illustrated inFIGS. 12, 32B, 33B, 34B, and 35B.

In some embodiments, one set of structures {(420 or 422) or 10B}selected from the second bonding pads (420 or 422) and the second subsetof the first light emitting devices 10B does not physically contact thesecond conductive bonding structures (430G or 432) when the first subsetof the first light emitting devices 10B are bonded to the backplane 401as illustrated in FIGS. 13, 32B, and 33B. In some embodiments, the firstconductive bonding structures (430B or 431) are bonded to the firstbonding pads (420 or 421) and the second conductive bonding structures(430G or 432) are bonded to the second bonding pads (420 or 422) before,and while, the first subset of the first light emitting devices 10B arebonded to the backplane 401 as illustrated in FIGS. 11 and 12 and asexplained above for the second through fifth exemplary integrated lightemitting device assemblies. In some embodiments, each of the first andconductive bonding structures (430B or 431) is bonded to a respectivefirst light emitting device 10B before, and while, the first subset ofthe first light emitting devices 10B are bonded to the backplane 401 asexplained above for the first exemplary integrated light emitting deviceassembly and as illustrated in FIGS. 32A, 32B, 33A, 33B, 34A, 34B, 35A,and 35B.

In some embodiments, proximal surfaces of the first light emittingdiodes 10B (i.e., surfaces that are closest to the backplane 401 such asthe bottom surfaces of the first light emitting diodes 10B) are within ahorizontal plane when the first assembly is disposed over the backplaneas illustrated in FIGS. 12, 32A, 32B, 33A, 33B, 34A, 34B, 35A, and 35B.The first bonding pads (420 or 421) are more proximal to the horizontalplane than the second bonding pads (420 or 422) are to the horizontalplane when the first assembly is disposed over the backplane 401 asillustrated in FIGS. 12, 32A, and 32B. In some embodiments, the firstbonding pads (421 have a greater thickness than the second bonding pads422 as illustrated in FIGS. 32A-32N. In some embodiments, backsidesurfaces of the first bonding pads 420 are vertically spaced from thehorizontal plane by a lesser separation distance than backside surfacesof the second bonding pads 420 are from the horizontal plane when thefirst assembly is disposed over the backplane 401 as illustrated in FIG.12. In some embodiments, the backplane 401 has stepped surfaces having adifferent separation distance from a planar backside surface 409 of thebackplane 401, and the first bonding pads 420 are located on a differentstepped surface than the second bonding pads 420 as illustrated in FIGS.9-12.

In some embodiments, the first bonding pads 421 and second bonding pads422 have a same thickness, and the first conductive bonding structures431 have a greater height than the second conductive bonding structures432 upon formation thereof, as illustrated in FIG. 33A.

In some embodiments, the second bonding pads 422 and the second subsetof the first light emitting devices 10B are in physically contact withthe second conductive bonding structures 432 when the first subset ofthe first light emitting devices 10B are bonded to the backplane 401, asillustrated in FIGS. 34B and 35B.

In some embodiments, the first conductive bonding structures 431 arebonded to an underlying first bonding pad 421 and an overlying firstlight emitting device 10B by irradiation by a laser beam thatselectively heats each first conductive bonding structure 10B asillustrated in FIG. 34B. In some embodiments, one set of structures (422or 10B) selected from the second bonding pads 422 and the second subsetof the first light emitting devices 10B is not bonded to the secondconductive bonding structures 432 when the first subset of the firstlight emitting devices 10B are bonded to the backplane 401.

In some embodiments, the first conductive bonding structures (430B or431) are bonded to an underlying first bonding pad (420 or 421) and anoverlying first light emitting device 10B by uniformly heating the firstconductive bonding structures (430B or 431) as illustrated in FIGS. 12,32B, 33B, and 35B.

In some embodiments, the second conductive bonding structures 432 arebonded to the second bonding pads 422 and to the second subset of thefirst light emitting devices 10B when the first subset of the firstlight emitting devices 10B are bonded to the backplane 401 asillustrated in FIG. 35B. In this case, each of the second conductivebonding structures 432 can be separated into two portions (432U, 432L)while separating the assembly comprising the first source substrate 301Band a second subset of the first light emitting devices 10B from thebackplane 401 as illustrated in FIG. 35D. The two portions (432U, 432L)can comprise an upper portion 432U bonded to a respective first lightemitting device 10B within the second set, and a lower portion 432Lbonded to a respective second bonding pad 421.

In some embodiments, the first subset of the first light emittingdevices 10B are bonded to the first bonding pad 421 and the secondsubset of the first light emitting devices 10B are bonded to the secondbonding pad 422 simultaneously at a reflow temperature at the processingstep of FIG. 35B. The laser ablation can be performed at a temperaturelower than the reflow temperature at the processing step of FIG. 35C. Atthe processing step of FIG. 35D, the assembly comprising the firstsource substrate 301B and the second subset of the first light emittingdevices 10B is separated from the backplane 401 at a separationtemperature, which can be selected to be not less than the reflowtemperature in some cases.

In some embodiments, the first subset of the first light emittingdevices 10B is pushed closer to the backplane while reflowing the firstconductive bonding structures after the assembly comprising the firstsource substrate 301B and the second subset of the first light emittingdevices 10B is separated from the backplane 401 as illustrated in FIGS.27, 28, 32E, 33E, 34E, and 35E. In some embodiments, a vertical pushingdistance during the pushing of the first subset of the first lightemitting devices 10B can be greater than a maximum height among gapsbetween the second conductive bonding structures (430G or 432) andstructures selected from overlying first light emitting diodes 10B andunderlying second bonding pads (420 or 422). The gaps can be presentbetween the second conductive bonding structures (430G or 432) andoverlying first light emitting diodes 10B as illustrated in FIGS. 12 and13, or can be present between the second conductive bonding structures(430G or 432) and underlying second bonding pads (420 or 422) asillustrated in FIGS. 32B and 33B.

In some embodiments, an additional assembly comprising another sourcesubstrate (401S or 101S) and sensor devices 10S can be provided. Thesensor devices 10S are not present in vacancy positions that formanother pattern, which can be, for example, the pattern of the vacancypositions in the fourth source substrate S in FIG. 31D. The additionalassembly comprising the additional source substrate (401S or 101S) andthe sensor devices 10S can be disposed over the backplane 401.Additional conductive bonding structures 420 can be disposed between thebackplane 401 and the additional assembly, and the vacancy positions inthe additional pattern overlie all areas of the first light emittingdevices 10B (and second and third light emitting devices (10G, 10R), ifpresent) that are bonded to the backplane 401 when the additionalassembly is disposed over the backplane 401 as illustrated in FIG. 19.While transfer of the sensor devices 10S to the backplane 401 is notexpressly described for the second through fifth integrated lightemitting device assemblies, it is understood that the same devicetransfer methods can be iteratively employed to transfer any number ofdifferent types of discrete devices in an array configuration having thesame pitches as the transferred discrete devices on the backplane 401.

In one embodiment, a first subset of the sensor devices 10S can bebonded to the backplane 401 through the additional conductive bondingstructures 420. The first subset of the sensor devices 20S can bedetached from the additional source substrate (401S or 101S) by laserablation of material portions 20 overlying the first subset of thesensor devices 10S as illustrated in FIG. 20. An assembly comprising theadditional source substrate (401S or 101S) and a second subset of thesensor devices 10S can be separated from the backplane 401 while thefirst subset of the sensor devices 10 remains bonded to the backplane401 as illustrated in FIG. 21.

In some embodiments, the first subset of the first light emittingdevices 10B is detached from the first source substrate (401B or 101B)one at a time by sequential irradiation of a laser beam to each firstlight emitting device 10B in the first subset as illustrated in FIGS.13, 32C, 33C, 34C, and 35C.

The first bonding pads (420, 421) are provided on the backplane 401, andeach of the first conductive bonding structures (430B or 431) is bondedto a respective first bonding pad (420, 421) and a respective firstlight emitting device 10B in the first subset when the first subset ofthe first light emitting devices 10B are bonded to the backplane 401. Insome embodiment, second conductive bonding structures (430G or 432) aredisposed between the second subset of the first light emitting devices10B and second bonding pads (420, 422) located on the backplane 401 at atime of bonding the first subset of the first light emitting diodes tothe backplane 401, and each second conductive bonding structure (430G or432) is bonded to one of an overlying first light emitting device 10Bwithin the second subset and an underlying second bonding pad (420,422), and does not physically contact another of the overlying firstlight emitting device 10B within the second subset and the underlyingsecond bonding pad (420, 422), as illustrated in FIGS. 13, 32B, and 33B.

In some embodiment, the backplane 401 is provided with steppedhorizontal surfaces at a top side as illustrated in FIGS. 9-23 and25-29. The stepped horizontal surfaces can comprise a first subset ofthe stepped horizontal surfaces located within a first horizontalsurface plane HSP1, and a second subset of the stepped horizontalsurfaces located within a second horizontal surface plane HSP2 that ismore proximal to a planar backside surface 409 of the backplane 401 thanthe first subset of stepped horizontal surfaces is to the planarbackside surface 409 of the backplane 401 as illustrated in FIG. 9. Inthis case, the first conductive bonding structures 420 can be formed atthe first subset of the stepped horizontal surfaces, and the secondconductive bonding structures 420 can be formed at the second subset ofthe stepped horizontal surfaces. The stepped horizontal surfaces cancomprise a third subset of the stepped horizontal surfaces is locatedwithin a third horizontal surface plane HSP3 that is more proximal tothe backside surface 409 of the backplane 401 than the second subset ofstepped horizontal surfaces is to the backside surface 409 of thebackplane 401, and the third conductive bonding structures 420 can beformed at the third subset of the stepped horizontal surfaces.

In one embodiment, the first assembly comprising the first sourcesubstrate (401B, 101B) and the first light emitting devices 10B canfurther comprise a release layer 20 contacting the first sourcesubstrate and comprising a material that absorbs light at a wavelengthselected from ultraviolet range, visible range, and infrared range. Abonding material layer 30 can contact the release layer 20 and the firstlight emitting devices 10B.

First portions of the release layer 20 (which is an ablation materiallayer 130) that overlies the first subset of the first light emittingdevices 10B can be removed selectively, while second portions of therelease layer 20 that overlie the second subset of the first lightemitting devices 10B are not removed. In some embodiments, the releaselayer 20 comprises silicon nitride, the laser wavelength is aultraviolet wavelength, and irradiating the first portions of therelease layer 20 with the laser beam ablates the first portions of therelease layer 20.

In some embodiments, the first source substrate can be an upper portion530 of a growth substrate 500B on which the first light emitting devices10B are fabricated. The first source substrate 101B can be provided byseparating the upper portion 530 of the growth substrate 500B from alower portion of the growth substrate 500B. In one embodiment, thegrowth substrate 500B can comprise a III-V compound semiconductormaterial, and can be a III-V compound semiconductor substrate.

According to some embodiments of the present disclosure, an integratedlight emitting device assembly is provided, which comprises a backplane401 having stepped horizontal surfaces at a top side. The steppedhorizontal surfaces comprises a first subset of the stepped horizontalsurfaces located within a first horizontal surface plane HSP1, and asecond subset of the stepped horizontal surfaces located within a secondhorizontal surface plane HSP2 that is more proximal to a backsidesurface 409 of the backplane 401 than the first subset of steppedhorizontal surfaces is to the backside surface 409 of the backplane 401as illustrated in FIG. 9. The integrated light emitting device assemblycan comprise conductive bonding structures 430 overlying the steppedhorizontal surfaces of the backplane 401. The conductive bondingstructures 430 comprise first conductive bonding structures 430Boverlying the first subset of the stepped horizontal surfaces and secondconductive bonding structures 430G overlying the second subset of thestepped horizontal surfaces. The integrated light emitting deviceassembly can comprise light emitting devices (10B, 10G, 10R) bonded tothe conductive bonding structures 430. The light emitting devices (10B,10G, 10R) can comprise first light emitting devices 10B that emit lightof a first wavelength and overlie the first subset of the steppedhorizontal surfaces and second light emitting devices 10G that emitlight of a second wavelength and overlie the second subset of steppedhorizontal surfaces.

In some embodiments, a first horizontal interfacial plane includinginterfaces between the first light emitting devices 10B and the firstconductive bonding structures 430B is more distal from the secondhorizontal surface plane than a second horizontal interface planebetween the second light emitting devices 10G and the second conductivebonding structures 430G as illustrated in FIGS. 22, 23, 24, 25, and 29.In some embodiments, the stepped horizontal surfaces further comprise athird subset of the stepped horizontal surfaces located within a thirdhorizontal surface plane HSP3 that is more proximal to the backsidesurface 409 of the backplane 401 than the second subset of steppedhorizontal surfaces as illustrated in FIG. 9. The conductive bondingstructures 430 can further comprise third conductive bonding structures430R overlying the third subset of the stepped horizontal surfaces.

In some embodiments, the light emitting devices (10B, 10G, 10R) furthercomprise third light emitting devices 10R that emit light of a thirdwavelength and overlie the third subset of the stepped horizontalsurfaces. A third horizontal interfacial plane including interfacesbetween the third light emitting devices 10R and the third conductivebonding structures 430R can be more proximal to the second horizontalsurface plane HSP2 than the second horizontal interface plane is to thesecond horizontal surface plane HSP2 as illustrated in FIGS. 22, 23, 24,25, and 29.

In some embodiments, the second conductive bonding structures 430G havea greater height than the first conductive bonding structures 430B asillustrated in FIGS. 22, 23, 24, 25, and 29. In some embodiments, thethird conductive bonding structures 430R have a greater height than thesecond conductive bonding structures 430G as illustrated in FIGS. 22,23, 24, 25, and 29. In some embodiments, the integrated light emittingdevice assembly can comprise sensor devices 10S bonded to the backplane401 through fourth conductive bonding structures 430S.

In some embodiment, a first horizontal top plane including top surfacesof the first light emitting devices 10B can be more proximal to thesecond horizontal surface plane HSP2 than a second horizontal top planeincluding top surfaces of the second light emitting devices 10G is tothe second horizontal surfaces plane HSP2 as illustrated in FIGS. 22,23, 24, 25, and 29.

In some embodiments, the light emitting devices (10B, 10G, 10R) furthercomprise third light emitting devices 10R that emit light of a thirdwavelength and overlie the third subset of the stepped horizontalsurfaces. A third horizontal top plane including top surfaces of thethird light emitting devices 10R can be more distal from the secondhorizontal surface plane than the second horizontal top plane is fromthe second horizontal surfaces plane as illustrated in FIGS. 22, 23, 24,25, and 29.

In some embodiments, the second light emitting devices 10G can have agreater height than the first light emitting devices 10G as illustratedin FIGS. 22, 23, 24, 25, and 29. In some embodiments, the third lightemitting devices 10R can have a greater height than the second lightemitting devices 10G.

In some embodiments, the light emitting devices (10B, 10G, 10R) can bearranged in a periodic array in which center-to-center distances ofneighboring light emitting devices along a horizontal direction areinteger multiples of a unit distance.

According to some embodiments of the present disclosure, an integratedlight emitting device assembly comprising first light emitting devices10B and second light emitting devices 10G bonded to a backplane 401 isprovided. Each first light emitting device 10B emits light at a firstwavelength, and each second light emitting device 10G emits light at asecond wavelength that is different from the first wavelength. Eachfirst light emitting device 10B is bonded to the backplane 401 through afirst stack including a first bonding pad (420 or 421) and a firstconductive bonding structure (430B or 431). Each second light emittingdevice 10G is bonded to the backplane 401 through a second stackincluding a second bonding pad (420 or 422) and a second conductivebonding structure (430G or 432). A first plane including firstinterfaces between the first bonding pads (420 or 421) and the firstconductive bonding structures (430B or 431) is vertically offset from asecond plane including second interfaces between the second bonding pads(420 or 422) and the second conductive bonding structures (430G or 432)as illustrated in FIGS. 22, 23, 24, 25, 29, and 32.

In some embodiments, distal surfaces (i.e., top surfaces) of the firstlight emitting devices 10B and the second light emitting devices 10G canbe within a same plane that is spaced from, and is parallel to, thefirst and second planes as illustrated in FIG. 32N. In some embodiments,the first bonding pads 421 can have a first thickness, and the secondbonding pads 422 can have a second thickness that is less than the firstthickness as illustrated in FIG. 32N.

In some embodiments, the first bonding pads 420 and the second bondingpads 420 can have a same thickness, and are located on stepped surfaces.Bottom surfaces of the first bonding pads 420 are located on a firstsubset of the stepped surfaces, and bottom surfaces of the secondbonding pads 420 are located on a second subset of the stepped surfacesthat are vertically offset from the first subset of the stepped surfacesas illustrated in FIGS. 22, 23, 24, 25, and 29.

In some embodiment, the first conductive bonding structures 432 have afirst height, and the second conductive bonding structures 432 have asecond height that is less than the first height as illustrated in FIG.32N. Each of the conductive bonding structures (431, 432, 433) can beformed with a same volume upon formation (for example, at the processingstep of FIG. 32A), and each of the first conductive bonding structures431 and the second conductive bonding structures 432 can have the samevolume. The first conductive bonding structures 431 and the secondconductive bonding structures 432 can have the same materialcomposition. In some embodiments, the first bonding pads 421 can have afirst thickness, the second bonding pads 422 can have a secondthickness, and the sum of the first thickness and the first height ofthe first conductive bonding structures 431 can be the same as the sumof the second thickness and the second height of the second conductivebonding structures 432 as illustrated in FIG. 32N.

In some embodiments, third light emitting devices 10R can be bonded tothe backplane 401. Each third light emitting device 10R emits light at athird wavelength that is different from the first wavelength and fromthe second wavelength. Each third light emitting device 10R can bebonded to the backplane 401 through a third stack including a thirdbonding pad 423 and a third conductive bonding structure 433. A thirdplane including third interfaces between the third bonding pads 423 andthe third conductive bonding structures 433 can be vertically offsetfrom the first plane and from the second plane.

According to some embodiments of the present disclosure, an integratedlight emitting device assembly comprising first light emitting devices10B and second light emitting devices 10G bonded to a backplane 401 isprovided. Each first light emitting device 10B emits light at a firstwavelength, and each second light emitting device 10G emits light at asecond wavelength that is different from the first wavelength. Eachfirst light emitting device 10B can be bonded to the backplane 401through a first stack including a first bonding pad 421 and a firstconductive bonding structure 431, and each second light emitting device10G can be bonded to the backplane 401 through a second stack includinga second bonding pad 422 and a second conductive bonding structure 432.The first conductive bonding structures 431 and the second conductivebonding structures 432 can have a same height. Each of the firstconductive bonding structures 431 can have a first volume, and each ofthe second conductive bonding structures 432 can have a second volumethat is less than the first volume as illustrated in FIG. 33N. The firstconductive bonding structures 431, the second conductive bondingstructures 432, and the third conductive bonding structures 433 can havedifferent volumes as formed at the processing step of FIG. 33A. Forexample, the volume of the first conductive bonding structures 431 canbe greater than the volume of the second conductive bonding structures432, and the volume of the second conductive bonding structures 432 canbe greater than the volume of the third conductive bonding structures433. The conductive bonding structures (431, 432, 433) can haveapproximately the same lateral extent and different vertical extents asformed at the processing step of FIG. 33A.

In some embodiments, distal surfaces (i.e., top surfaces) of the firstlight emitting devices 10B and the second light emitting devices 10G canbe within a same horizontal plane that is spaced from, and is parallelto, a top surface of the backplane 401, and a backside surface 409 ofthe backplane 401.

In some embodiments, the first bonding pads 421 and the second bondingpads 422 can have the same thickness as illustrated in FIG. 33N. In someembodiments, bottom surfaces of the first bonding pads 421 and thesecond bonding pads 422 can be located within a same plane including atop surface of the backplane 401. In some embodiments, the firstconductive bonding structures 421 and the second conductive bondingstructures 422 can have a same material composition.

In some embodiments, third light emitting devices 10R can be bonded tothe backplane 401. Each third light emitting device 10R emits light at athird wavelength that is different from the first wavelength and fromthe second wavelength. Each third light emitting device 10R can bebonded to the backplane 401 through a third stack including a thirdbonding pad 423 and a third conductive bonding structure 433. The firstconductive bonding structures 431, the second conductive bondingstructures 432, and the third conductive bonding structures 433 can havethe same height, and each of the third conductive bonding structures 433can have a third volume that is less than the second volume.

According to an aspect of the present disclosure, ultra low temperaturebonding for thermally sensitive processes can be designed around lowmelting point metals, eutectics and rapid diffusion reactions. Combiningseparate bond pad combinations leads to a process called selective diebonding. While the present disclosure is described employing acombination of three materials including indium (In), tin (Sn), andtellurium (Te), a combination of any plurality of materials selectedfrom Table 1 below and having different melting temperatures can beemployed as a set of solder materials in conjunction with correspondingbond pad metallurgy to enable sequential bonding of dies (devices) inmultiple stages.

Further, various types of bond materials can be employed to implementthe features of the present disclosure. Three embodiments include: fullyreversible pure metal bonds; partially reversible eutectic reactions;and nearly irreversible low temperature diffusion reactions.

Fully reversible pure metal bonds with In (melting point 156° C.), Sn(melting point 232° C.) and Te (melting point 449° C.) are deposited onone or both sides of the devices to be bonded. The bond interface can beremelted and reworked several times. Each metal must be deposited on topof appropriate diffusion barriers and adhesion layers consistent withthe underlying device or substrate. For example, Sn can be employed onPt/Ti/Cr. The thickness of the layer may range from 10 nm to severalmicrons. Lateral flow of the molten solder is controlled by bondingconditions, bond pad geometry, wetting layer design and thermalcompression bonding parameters.

Partially reversible eutectic reactions are bonds in which the alloysystem includes a series of cascading eutectic reactions in the phasediagram (e.g. the Cu—Sn) system or has an extended two phase liquid plussolid phase region adjoining the eutectic point. These bonds arepartially reversible when the composition of the bond interface isengineered such that the mixing (diffusion) of the two alloyingcomponents increases in temperature of the alloy but still contains purecomponents and solid solutions with a low melting point. The reaction ispartially reversible since the reacted alloy will form intermetalliccompounds that do not remelt at low temperature. This type of diebonding method can also result in permanent bond when the thicknesses ofthe metal layers is engineered to result in full consumption of thelower melting point material into higher stability intermetalliccompounds. These system will generally allow at least one remelt andrebond sequence and as many as four or more (Au—Sn). The first bond willbe done slightly above the melting point of the lowest meltingcomponent. Rework temperature will be approximately 10° C.-15° C. higherthan the first bond temperature. As more and more of the highertemperature component is consumed in the alloy formation therebond/rework temperatures will rise. Each metal must be deposited ontop of appropriate diffusion barriers and adhesion layers consistentwith the underlying device or substrate. For example, Sn can be employedon Pt/Ti/Cr. The thickness of the layer may range from 10 nm to severalmicrons. Lateral flow of the molten solder is controlled by bondingconditions, bond pad geometry, wetting layer design and thermalcompression bonding parameters.

Nearly irreversible low temperature diffusion reactions are systemswhere it may be possible to rework the bond joint only once owing to therapid diffusion process and formation of stable high temperaturecompounds. The reactions are rapid but can be used with rapid thermalprocesses to arrest the compound formation and allow for melting ofremaining lower temperature solid solution. Each metal must be depositedon top of appropriate diffusion barriers and adhesion layers consistentwith the underlying device or substrate. For example, Sn can be employedon Pt/Ti/Cr. The thickness of the layer may range from 10 nm to severalmicrons. Lateral flow of the molten solder is controlled by bondingconditions, bond pad geometry, wetting layer design and thermalcompression bonding parameters.

The exemplary systems include, but are not limited to, those withreaction temperatures below 450° C. that have been shown to be partiallyor fully reversible. The pure metal, fully reversible systems are In—In,Sn—Sn, and Te—Te. The fully and partially reversible bonds include oneor more of In, Sn or Te. For tin based joints the most notable examplesare In—Sn, Cu—Sn, Au—Sn, Ag—Sn, Al—Sn, Pd—Sn, Ge—Sn, Ni—Sn. For indiumbased joints the most significant systems are In—Sn, Ag—In, Au—In,Cu—In, In—Pt, In—Pd. The tellurium systems of interest are In—Te, Sn—Te,Ag, Te, Cu—Te, and Ge—Te.

Combing these basic low temperature reactions in selective areas of abonded system allows selective transfer of mixed technologies or dietypes. The substrate can be provided with solder materials of differenttypes. In one embodiment, the solder materials can be embodied as theconductive bonding structures (430, 431, 432, 433) described above.Alternatively, if a bonding scheme employs direct bondpad-to-bondpadbonding, the bondpads (420, 421, 422, 423) described above can includethe solder materials.

For example if a support substrate is composed of bond pads of In, Snand Te and the mating part(s) have bond pads of copper the followingsequence could be used to selectively bond parts only at In, Sn, or Telocations.

First, starting with the first material (e.g., In) having a firsteutectic point with Cu (which is the lowest eutectic point among thethree eutectic points), the substrate can be heated to just over thefirst eutectic point (e.g., 156° C. for the case of the In—Cu system)and contacted by a first Cu-pad containing die, i.e., a first device 10Bincluding copper bonding pads. This will form a eutectic alloy, anddepending upon the length of time and temperature, the first Cu-padcontaining die is held in contact the joint will form a stableintermetallic that will not remelt until above 310° C. during subsequentreheating processes. No other location with the Sn or Te willappreciably react with the Cu material at such a low temperature.

Second, a second Cu-pad containing die, i.e., a second device 10Gincluding copper bonding pads, can be bonded to the substrate by placingthe second Cu-pad containing die and raising the temperature of thecontacted parts to just above the second eutectic point of the secondmaterial (e.g., Sn) with Cu. The second eutectic point is higher thanthe first eutectic point, and is lower than the third eutectic point ofthe third material with Cu. In case Sn is the second material, thesecond eutectic temperature is 186° C. The substrate can be heated tojust over the second eutectic point and contacted by the second Cu-padcontaining die, i.e., the copper bonding pad(s) of the second device10G. This will form a eutectic alloy, and depending upon the length oftime and temperature, the second Cu-pad containing die is held incontact the joint will form a stable intermetallic that will not remeltuntil above 340° C. during subsequent reheating processes. Theintermetallics stabilize the joint.

Last, a third Cu-pad containing die, i.e., a third device 10R includingcopper bonding pads, can be bonded to the substrate by placing the thirdCu-pad containing die and raising the temperature of the contacted partsto just above the third eutectic point of the third material (e.g., Te)with Cu. If the third material is Te, the third eutectic temperature isabout 340° C.

Additional bonding schemes are provided, in which a substrate (such as abackplane 401) and a die (which can be any of the devices) have multiplecombined metallurgies of staggered reaction temperatures. For example,the substrate can contain sites with In, Sn and Te bonding pads. A firstdie (such as a first light emitting device 10B) with at least one Aubonding pad can be joined to the In sites at 144° C., a second die (suchas a second light emitting device 10G) with at least one Cu bonding padcan be joined to the Sn sites at 186° C.-227° C., and a third die (suchas third light emitting device 10R) with at least one Ag bonding pad canbe joined to the Te sites at 295° C.-353° C. Many combinations arepossible and the thickness of the layers of the various types of bondingpads can be adjusted such that at each selective die attach stage thereis enough remaining In, Sn, or Te to enable remelting and rework of theindividual bonds.

The various methods of employing multiple types of solder materialshaving different eutectic temperatures with a common bonding padmaterial (such as Cu, Au, Ag, Sn, or In) can be employed in conjunctionwith any of the die (device) transfer methods described above.

Table 1 lists the metallurgical systems of interest and the lowest bondtemperature for initial selective die attach.

TABLE 1 Exemplary eutectic systems and respective eutectic temperaturesthat can be employed to provide a set of eutectic systems havingdifferent eutectic temperatures for various bonding schemes of thepresent disclosure. Binary Alloy System Lowest Bond Temp (° C.) Au—Pd100 In—Sn 120 Ag—In 144 Au—In 153 Cu—In 153 In—Pt 154 In—Pd 156 In—Te156 Cu—Sn 186 Sn—Zn 199 Au—Sn 217 Ag—Sn 221 Al—Sn 228 Sn—Te 228 Pd—Sn230 Ge—Sn 231 Ni—Sn 231 Sn—Ti 231 Cr—Sn 232 Nb—Sn 232 Sn—Sn 232 Au—Cu240 Cu—Ni 250 Ag—Te 295 Cu—Te 340 Al—Cr 350 Au—Ge 360 Au—Si 363 Ge—Te365 Cu—Pd 400 Cu—Pt 418

Referring to FIG. 36, an exemplary structure is illustrated, whichincludes a substrate 802 and a single crystalline n-doped galliumnitride layer 804. In one embodiment, the substrate 802 can be a singlecrystalline substrate on which a III-V compound semiconductor materialcan be epitaxially deposited. For example, the substrate 802 can be asapphire (aluminum oxide) layer having a c-plane (0001 plane) as thecrystallographic plane of the top surface.

The single crystalline n-doped gallium nitride layer 804 includes asingle crystalline gallium nitride material in epitaxial alignment withthe crystalline structure of the substrate 802. The single crystallinen-doped gallium nitride layer 804 can be formed, for example, by anepitaxial deposition process such as metal-organic chemical vapordeposition (MOCVD) process. The thickness of the single crystallinen-doped gallium nitride layer 804 can be selected such that dislocationdefects caused by lattice mismatch between the lattice parameters of thesubstrate 802 and gallium nitride are healed, and the defect densitydecreases to a level suitable for device fabrication at the top surfaceof the single crystalline n-doped gallium nitride layer 804. Forexample, the thickness of the single crystalline n-doped gallium nitridelayer 804 can be in a range from 1.2 microns 6 microns, although lesserand greater thicknesses can also be employed. The single crystallinen-doped gallium nitride layer 804 may be doped with electrical dopantsof a first conductivity type. For example, the single crystallinen-doped gallium nitride layer 804 may be n-doped by introduction ofsilicon as n-type dopants during the epitaxial deposition process.

A single crystalline n-doped indium gallium nitride layer 808 isdeposited on the single crystalline n-doped gallium nitride layer 804 byan epitaxial deposition method. In one embodiment, the singlecrystalline n-doped indium gallium nitride layer 808 can be formed witha graded composition such that the indium concentration graduallyincreases with distance from the top surface of the single crystallinen-doped gallium nitride layer 804. In one embodiment, the ratio of theatomic concentration of indium atoms to the sum of the atomicconcentration of indium atoms and the atomic concentration of galliumatoms (i.e., an indium to Group III ratio) in the lower portion of thesingle crystalline n-doped indium gallium nitride layer 808 may be in arange from 0.001 to 0.4, such as from 0.01 to 0.2. The indium to GroupIII ratio in the upper portion of the single crystalline n-doped indiumgallium nitride layer 808 may be in a range from 0.1 to 0.7, such asfrom 0.3 to 0.6, although lesser and greater ratios can also beemployed. The thickness of the single crystalline n-doped indium galliumnitride layer 808 can be in a range from 1.5 microns to 10 microns, suchas from 2 microns to 5 microns, although lesser and greater thicknessescan also be employed.

An active layer 810 is formed on the single crystalline n-doped indiumgallium nitride layer 808. The active layer 810 includes at least onesemiconductor material that emits light upon application of a suitableelectrical bias. For example, the active layer 810 can include amulti-quantum well (MQW) structure that is conductive to emission of redlight upon application of an electrical bias thereacross. For example,the active layer 810 can include a multi-quantum well including multiplerepetitions of a combination of an indium gallium nitride layer having afirst thickness (which may be in a range from 1 nm to 10 nm) andaluminum gallium nitride layer (which may be in a range from 0.5 nm to 5nm). A series of epitaxy processes can be employed to grow the activelayer 810. The thickness of the active layer 810 can be in a range from20 nm to 1 micron, although lesser and greater thicknesses can also beemployed. The active layer 810 can be configured to emit red light at apeak wavelength in a range from 620 nm to 750 nm upon application of anelectrical bias thereacross. In one embodiment, the active layer 810 caninclude at least one instance of an indium gallium nitride layer and atleast one instance of a compound semiconductor material layer having agreater band gap than the at least one indium gallium nitride layer.

In one embodiment, the active layer 810 can be a planar layer having auniform thickness between a top surface and a bottom surface that areparallel to the top surface of the single crystalline n-doped galliumnitride layer 804. In one embodiment, the active layer 810 can include amulti quantum well structure including multiple instances of the indiumgallium nitride layer and the compound semiconductor material layer. Inone embodiment, the compound semiconductor material layer comprisesaluminum gallium nitride. In one embodiment, the indium to Group IIIratio (e.g., In/(In+Ga) ratio) of the indium gallium nitride layers inthe active layer 810 may be in a range from 0.25 to 0.5, such as from0.3 to 0.4. The aluminum to Group III ratio (e.g., Al/(Al+Ga) ratio) ofthe aluminum gallium nitride may be 0.5 to 0.98, such as 0.85 to 0.95,for example 0.9 to 0.94.

In one embodiment, the active layer may comprise the InGaN based quantumwells described by Hwang et al., Applied Physics Express 7, 071003(2014), incorporated herein by reference in its entirety. Specifically,Hwang et al. describe a 4 period InGaN quantum well embedding an AlGaNinterlayer with an Al content of 90% in each interlayer, located over ac-plane sapphire substrate. The indium content in the 3 nm thick InGaNquantum well is about 35% and less than 1% in the 1 nm thick AlGaNinterlayer.

A p-doped compound semiconductor material layer 812 can be formed on theactive layer 810. The p-doped compound semiconductor material layer 812can include a single crystalline compound semiconductor material such asindium gallium nitride. In one embodiment, the indium to Group III ratioof the p-doped compound semiconductor material layer 812 can be the sameas, or can be substantially the same as, the indium to Group III ratioof the single crystalline n-doped indium gallium nitride layer 808 inorder to minimize strain caused by lattice mismatch. The thickness ofthe p-doped compound semiconductor material layer 812 can be in a rangefrom 300 nm to 3 microns, although lesser and greater thicknesses canalso be employed.

A transparent conductive electrode, such as a transparent conductiveoxide layer 964 can be deposited over the p-doped compound semiconductormaterial layer 812. In case light emitted from the active layer 810 isdirected downward toward the single crystalline n-doped gallium nitridelayer 804 by a reflector layer to be subsequently formed above thetransparent conductive electrode, then the transparent conductive oxidelayer 964 is herein referred to a backside transparent conductive oxidelayer 964. The transparent conductive oxide layer 964 includes atransparent conductive oxide material such as indium tin oxide oraluminum doped zinc oxide. The transparent conductive oxide layer 964can be deposited as a continuous material layer that extends across theentire area of the p-doped compound semiconductor material layer 812.The thickness of the transparent conductive oxide layer 964 can be in arange from 100 nm to 2 microns, such as from 200 nm to 1 micron,although lesser and greater thicknesses can also be employed.

Optionally, a reflector material can be deposited to form a reflectorlayer 966 that continuously extends over the backside transparentconductive oxide layer 964 and the active layer 810. The reflector layer966 is electrically shorted to the p-doped compound semiconductormaterial layer 812 through the backside transparent conductive oxidelayer 964. In one embodiment, the reflector layer 966 includes at leastone material selected from silver, aluminum, copper, and gold. In oneembodiment, the reflector material can be deposited by a directiondeposition method such as physical vapor deposition (sputtering) orvacuum evaporation. The reflector layer 966 can be employed to reflectlight emitted from the active layer 810 downward.

An optional dielectric material is deposited over the reflector layer966 and to form a dielectric material layer 970. The dielectric materiallayer 970 is formed over, and around, the reflector layer 966. Thedielectric material of the dielectric material layer 970 can be aself-planarizing dielectric material such as spin-on glass (SOG) thatcan be formed by spin coating. Alternatively, the dielectric material ofthe dielectric material layer 970 can be a non-self-planarizingmaterial. In this case, the dielectric material layer 970 may, or maynot, be subsequently planarized. If the dielectric material layer 970 isplanarized, a chemical mechanical planarization (CMP) process can beemployed. In one embodiment, the dielectric material of the dielectricmaterial layer 970 can include doped silicate glass or undoped silicateglass. The thickness of the dielectric material layer 970 can be in arange from 100 nm to 4 microns, such as from 200 nm to 2 microns,although lesser and greater thicknesses can also be employed.

Referring to FIG. 37, openings can be formed through the dielectricmaterial layer 970 to a top surface of the reflector layer 966. Forexample, a photoresist layer (not shown) can be applied over thedielectric material layer 970, and can be lithographically patterned toform openings therein. The pattern of the openings in the photoresistlayer can be transferred through the dielectric material layer 970 by ananisotropic etch or an isotropic etch to form the openings in thedielectric material layer 970. For example, a wet etch employinghydrofluoric acid or a reactive ion etch employing a fluorocarbonetchant can be employed to form the opening through the dielectricmaterial layer 970. In one embodiment, one opening through thedielectric material layer 970 can be formed per one die area, i.e., pereach portion of the active layer 810 to be employed for a singlered-light emitting subpixel.

At least one metallic barrier layer (984, 986) can be formed as at leastone continuous material layer over the top surface of the dielectricmaterial layer 970 and in the opening through the dielectric materiallayer 970. The at least one metallic barrier layer (984, 986) can beformed directly on the reflector layer 966. The at least one metallicbarrier layer (984, 986) extends vertically through the openings throughthe dielectric material layer 970, and is electrically shorted to thereflector layer 966, the transparent conductive oxide layer 954, and thep-doped compound semiconductor material layer 812.

The at least one metallic barrier layer (984, 986) includes metallicmaterial layers that can be employed for under-bump metallurgy (UBM),i.e., a set of metal layers provide between a solder bump and a die. Inone embodiment, the at least one metallic barrier layer (984, 986) caninclude a diffusion barrier layer 984 and an adhesion promoter layer986. Exemplary materials that can be employed for the diffusion barrierlayer 984 include titanium and tantalum. Exemplary materials that can beemployed for the adhesion promoter layer 986 include a stack, frombottom to top, of copper and nickel, tungsten, platinum, and a stack oftungsten and platinum. Any other under-bump metallurgy known in the artcan also be employed. The at least one metallic barrier layer (984, 986)includes a horizontal portion that overlies the dielectric materiallayer 970 and a vertically protruding portion that adjoins an innerperiphery of the horizontal portion and contacting sidewalls of thedielectric material layer 970 and the reflector layer 966.

A conductive bonding structure 433 (such as a solder bump) can be formedin each cavity within the openings in the dielectric material layer 970and over a portion of the top surface of the at least one metallicbarrier layer (984, 986) located around the opening in the dielectricmaterial layer 970. If the conductive bonding structure 433 can be asolder bump that includes a solder material, which can include tin, andoptionally includes silver, copper, bismuth, indium, zinc, and/orantimony. The upper portion of the conductive bonding structure 433located above the horizontal plane including the top surface of the atleast one metallic barrier layer (984, 986) can have a shape of apredominant portion of a sphere. It is understood that shape of theconductive bonding structure 433 as illustrated is only schematic, andmay not represent a true shape of a conductive bonding structure 433.The lower portion of the conductive bonding structure 433 fills theopening in the dielectric material layer 970.

If the conductive bonding structure 433 has a shape of a predominantportion of a sphere, the diameter of the sphere can be in a range from15 microns to 60 microns, although lesser and greater diameters can alsobe employed. The lower portion of the conductive bonding structure 433can be formed directly on a sidewall of the at least one metallicbarrier layer (984, 986) within the opening through the dielectricmaterial layer 970 and directly on a top surface of a recessed portionof the at least one metallic barrier layer (984, 986). The conductivebonding structure 433 is electrically shorted to the reflector layer966, the transparent conductive oxide layer 954, and the p-dopedcompound semiconductor material layer 812.

Referring to FIG. 38, the substrate 802 can be optionally removed. Forexample, laser beam can pass through the substrate 802 (including amaterial such as sapphire) and ablate the bottom surface region of thesingle crystalline n-doped gallium nitride layer 804, thereby detachingthe substrate 802 from remaining portions of the single crystallinen-doped gallium nitride layer 804 and the structures thereupon. Thephysically exposed surface of the single crystalline n-doped galliumnitride layer 804 is herein referred to as a distal surface, i.e., asurface that is distal from the active region 810. The exemplarystructure can be subsequently singulated and/or transferred to form adisplay device including red-light emitting diodes. Each singulated diecan be a red-light emitting diode, which can be employed as a thirdlight emitting device 10R described above.

In one embodiment, an electrode for each light emitting diode can beformed on a respective conductive bonding structure 433, and anotherelectrode for each light emitting diode can be formed on a respectiveportion of the distal surface of the single crystalline n-doped galliumnitride layer 804.

FIG. 39 illustrates the assembly process in which a red-light emittingdevice 10R is bonded to a backplane 401, which may be any one of thebackplanes described above. In case two conductive bonding structures(431, 432, or 433) are formed per device (10B, 10G, 10R), each of thetwo conductive bonding structures (431, 432, or 433) can be connected toa respective node of a light emitting device. In case only oneconductive bonding structure (431, 432, or 433) is formed per device(10B, 10G, 10R), the conductive bonding structure (431, 432, or 433) isconnected to one node of the respective device (10B, 10G, 10R), and amaterial portion in each device (10B, 10G, 10R) located on the oppositeside of the conductive bonding structure (431, 432, or 433) is connectedto the other node of the respective device (10G, 10G, 10R).

In the case of red-light emitting diode 10R illustrated in FIG. 38 isemployed in the structure of FIG. 39, the p-doped compound semiconductormaterial layer 812 is electrically connected to the conductive bondingstructure 433 thereupon, and the single crystalline n-doped galliumnitride layer 804 can be the topmost surface of the red-light emittingdiode 10R shown in FIG. 39.

Referring to FIG. 40A, a dielectric fill material layer 798 can beapplied in the spaces between the devices (10B, 10G, 10R) that arebonded to the backplane 401. While FIG. 40A illustrates only threedevices (10B, 10G, 10R), it is understood that an array of pixels isformed on the backplane 401, and each pixel includes a set of lightemitting device such as a blue-light emitting diode as a first lightemitting device 10B, a green-light emitting diode as a second lightemitting device 10G, and a red-light emitting diode as a third lightemitting device 10R. The dielectric fill material layer 798 canlaterally surround each of the red-light emitting diodes, thegreen-light emitting diodes, and the blue light emitting diodes withinthe array of pixels. The dielectric fill material layer 798 can includea self-planarizing dielectric material such as spin-on glass (SOG), orcan be planarized by a recess etch or chemical mechanical planarization.The top surface of the dielectric fill material layer 798 as planarizedcan be within the horizontal plane including the top surfaces of thedevices (10B, 10G, 10R), or can be vertically recessed below thehorizontal plane including the top surfaces of the devices (10B, 10G,10R).

Referring to FIG. 40B, a front side transparent conductive oxide layer796 can be formed over the dielectric fill material layer 798 anddirectly on the electrical nodes that are located on top of each device(10B, 10G, 10R). For example, each red-light emitting diode can includea single crystalline n-doped gallium nitride layer 804 as the physicallyexposed node. In case the green-light emitting diodes and/or theblue-light emitting diodes include a single crystalline n-doped galliumnitride layer as physically exposed nodes at top, the front sidetransparent conductive oxide layer 796 can be deposited directly on sucha single crystalline n-doped gallium nitride layer. In this case, thefront side transparent conductive oxide layer 796 can be a common groundelectrode for each of the red-light emitting diodes, the green-lightemitting diodes, and the blue-light emitting diodes.

A transparent passivation dielectric layer 794 can be formed over thefront side transparent conductive oxide layer 796. The transparentpassivation dielectric layer 794 can include silicon nitride or siliconoxide.

The red-light emitting diodes of the type illustrated in FIG. 38 can beemployed without, or in combination with, the blue-light emitting diodesand/or the green-light emitting diodes of the type described above inthe direct view display device of FIG. 40B. Such a direct view displaydevice comprises an array of pixels located on a backplane 401. Each ofthe pixels comprises a red-light emitting diode configured to emit lightat a peak wavelength in a range from 620 nm to 750 nm, a green-lightemitting diode configured to emit light at a peak wavelength in a rangefrom 495 nm to 570 nm, and a blue-light emitting diode configured toemit light at a peak wavelength in a range from 450 to 495 nm. Thered-light emitting diode in each pixel comprises: a first singlecrystalline n-doped gallium nitride layer 804; a single crystallinen-doped indium gallium nitride layer 808 in epitaxial alignment with thesingle crystalline n-doped gallium nitride layer 804; an active layer810 including at least one instance of an indium gallium nitride layerand at least one instance of a compound semiconductor material layerhaving a greater band gap than the at least one indium gallium nitridelayer; and a first p-doped compound semiconductor material layer 812,wherein the active layer is configured to emit light at a peakwavelength in a range from 620 nm to 750 nm upon application ofelectrical bias between the single crystalline n-doped indium galliumnitride layer 808 and the p-doped compound semiconductor material layer812.

In one embodiment, the active layer 810 is a planar layer having auniform thickness between a top surface and a bottom surface that areparallel to a top surface of the single crystalline n-doped galliumnitride layer 804. In one embodiment, the active layer 810 includes amulti quantum well structure including multiple instances of the indiumgallium nitride layer and the compound semiconductor material layer. Inone embodiment, the compound semiconductor material layer comprisesaluminum gallium nitride.

Each of the red-light emitting diodes 10R, the green-light emittingdiodes 10G, and the blue light emitting diodes 10B can be a planar LEDor a nanowire LED.

In one embodiment, the red-light emitting diode in each pixel comprisesa first conductive bonding structure 433 (such as a solder bump) that iselectrically shorted to the first p-doped compound semiconductormaterial layer 812 and is bonded to a respective bonding pad 423 on thebackplane 401; and the at least one of the green-light emitting diode10G, and the blue-light emitting diode 10B in each pixel comprises asecond conductive bonding structure (431 or 432) (such as a solder bump)that is electrically shorted to the second p-doped compoundsemiconductor material layer and is bonded to another respective bondingpad (421 or 422) on the backplane 401.

In one embodiment, the red-light emitting diode 10R in each pixelcomprises a first reflector layer 966 that is located between the firstp-doped compound semiconductor material layer 812 and the firstconductive bonding structure 433 and configured to reflect light towardthe first single crystalline n-doped gallium nitride layer 804.

In one embodiment, the red-light emitting diode 10R in each pixelcomprises a first transparent conductive oxide layer 964 that is locatedbetween, and electrically shorted to, the first p-doped compoundsemiconductor material layer 812 and the first conductive bondingstructure 433.

In one embodiment, the direct view display device can further include: adielectric fill material layer 798 laterally surrounding each of thered-light emitting diodes 10R, the green-light emitting diodes 10G, andthe blue light emitting diodes 10B within the array of pixels; and afront side transparent conductive oxide layer 796 located on thedielectric fill material layer 798 and electrically shorted to eachinstance of the first and second single crystalline n-doped galliumnitride layers 804 within the array of pixels.

Referring to FIG. 41, a first exemplary planar material layer stackaccording to an embodiment of the present disclosure is shown. The firstexemplary planar material layer stack can be formed by providing asubstrate 802, which can be a single crystalline substrate on which aIII-V compound semiconductor material can be epitaxially deposited. Forexample, the substrate 802 can be a sapphire (aluminum oxide) substratehaving a c-plane (0001 plane) as the crystallographic plane of the topsurface. The substrate 802 can have a planar top surface. As usedherein, a “planar” surface refers to a surface that is substantiallycoincident with a Euclidean two-dimensional plane within the variationscaused by surface roughness.

A single crystalline gallium nitride (GaN) layer 804 can be grown by anepitaxial deposition process. The gallium nitride layer 804 may beunintentionally or intentionally n-doped. The single crystalline n-dopedgallium nitride layer 804 includes a single crystalline gallium nitridematerial grown on the substrate 802 (such as a single crystallinesapphire substrate). At the time of deposition, the single crystallinen-doped gallium nitride layer 804 is a planar single crystalline n-dopedGaN layer having a planar top surface and a planar bottom surface thatare parallel to the planar top surface of the substrate 802. The singlecrystalline n-doped gallium nitride layer 804 can be formed, forexample, by an epitaxial deposition process such as metal-organicchemical vapor deposition (MOCVD) process. The thickness of the singlecrystalline n-doped gallium nitride layer 804 can be selected such thatdislocation defects caused by lattice mismatch between the latticeparameters of the substrate 802 and gallium nitride are healed, and thedefect density decreases to a level suitable for device fabrication atthe top surface of the single crystalline n-doped gallium nitride layer804. In a non-limiting illustrative example, the thickness of the singlecrystalline n-doped gallium nitride layer 804 can be in a range from 1.2microns to 6 microns, although lesser and greater thicknesses can alsobe employed. The single crystalline n-doped gallium nitride layer 804may be doped with electrical dopants of a first conductivity type. Forexample, the single crystalline n-doped gallium nitride layer 804 may ben-doped by introduction of silicon as n-type dopants during theepitaxial deposition process. Upon singulation of the first exemplaryplanar material layer stack in a subsequent process, each discreteportion of the single crystalline n-doped gallium nitride layer 804becomes a single crystalline n-doped GaN portion within a respectivelight emitting device, which can be a first light emitting device 10R.

In one embodiment, a planar layer stack (1110, 1118, 1120, 1130, 1140,1150, 1160) is formed on the single crystalline n-doped gallium nitridelayer 804. The planar layer stack (1110, 1118, 1120, 1130, 1140, 1150,1160) can include an epitaxial material layer stack (i.e., a stack ofepitaxial material layers that are epitaxially aligned among oneanother) that includes, in order, one or more of planar superlatticestructures (1110, 1120) comprising respective strain-modulating layerstacks (1112, 1114) and/or (1112, 1124), a planar light-emitting quantumwell that includes a planar light-emitting indium gallium nitride layer1132 and a planar GaN barrier layer 1134, and a planar p-dopedIII-nitride layer 1140, which is preferably a p-doped aluminum galliumnitride layer. However, the p-doped III-nitride layer 1140 mayalternatively comprise gallium nitride or indium aluminum galliumnitride with a low indium content. The plurality of planar superlatticestructures (1110, 1120) can modulate, and reduce, the strain of theplanar light-emitting InGaN layer 1132, thereby enabling high indiumincorporation with low defect formation and thus enabling high emissionefficiency across the red wavelength range. The planar light-emittingindium gallium nitride layer 1132 is configured to emit light at a firstpeak wavelength in a range from 600 nm to 750 nm under electrical biasthereacross. In one embodiment, the first peak wavelength can be in arange from 610 nm to 680 nm.

In an illustrative example, the plurality of strain-modulating layerstacks can include first strain-modulating layer stacks (1112, 1114) andsecond strain-modulating layer stacks (1122, 1124). Each firststrain-modulating layer stack (1112, 1114) can include a firstintervening indium gallium nitride layer 1112 and a first interveningGaN layer 1114. Each second strain-modulating layer stack (1122, 1124)can include a second intervening indium gallium nitride layer 1122 and asecond intervening GaN layer 1124. In an alternative embodiment, atleast one layer among the first intervening GaN layers 1114 and thesecond intervening GaN layers 1124 may be replaced with a respectiveintervening aluminum gallium nitride layer or indium gallium nitridelayer having a different indium concentration than the first interveningindium gallium nitride layers 1112 or the second intervening indiumgallium nitride layers 1122 within the respective strain-modulatinglayer stack.

In one embodiment, the first intervening indium gallium nitride layers1112 can have a lower indium concentration than the second interveningindium gallium nitride layers 1122. For example, the first interveningindium gallium nitride layers 1112 can have a composition ofIn_(p)Ga_((1-p))N in which p is in a range from 0.04 to 0.08, althoughlesser and greater values for p can also be employed. The secondintervening indium gallium nitride layers 1122 can have a composition ofIn_(q)Ga_((1-q))N in which q is in a range from 0.08 to 0.12, althoughlesser and greater values for q can also be employed.

The first strain-modulating layer stacks (1112, 1114) containing thelower indium concentration first intervening indium gallium nitridelayers 1112 can be considered as “UV” stacks (e.g., which would emit UVradiation having a peak wavelength less than 400 nm). The secondstrain-modulating layer stacks (1122, 1124) containing the higher indiumconcentration second intervening indium gallium nitride layers 1122 canbe considered as “blue” stack (e.g., which would emit blue visible lighthaving a peak wavelength between 400 nm and 495 nm).

The thickness of each first intervening indium gallium nitride layer1112 can be in a range from 0.7 nm to 1.5 nm, although lesser andgreater thicknesses can also be employed. The thickness of each firstintervening GaN layer 1114 can be in a range from 3 nm to 6 nm, althoughlesser and greater thicknesses can also be employed. The thickness ofeach second intervening indium gallium nitride layer 1122 can be in arange from 2 nm to 3 nm, although lesser and greater thicknesses canalso be employed. The thickness of each second intervening GaN layer1124 can be in a range from 15 nm to 20 nm, although lesser and greaterthicknesses can also be employed.

The layers of the first and the second superlattice structures (1110,1120) may be not intentionally doped with p-type or n-type dopants. SuchIII-nitride layers that are not intentionally doped typically haven-type conductivity.

Without wishing to be bound by any particular theory, it is believedthat it is possible that due to the higher indium content of the secondintervening indium gallium nitride layers 1122 in the secondstrain-modulating layer stacks (1122, 1124) of the second superlatticestructure 1120 than of the first intervening indium gallium nitridelayers 1112 in the second strain-modulating layer stacks (1122, 1124) ofthe first superlattice structure 1110, the effective lattice constant ofthe second superlattice structure 1120 is greater than the effectivelattice constant of the first superlattice structure 1110.

The first superlattice structure 1110 can include 3 to 30, such as 10 to15 first strain-modulating layer stacks (1112, 1114), although lesserand greater number of repetitions can also be employed. The totalthickness of the first multi quantum well structure 1110 can be in arange from 20 nm to 150 nm, although lesser and greater thicknesses canalso be employed.

The second superlattice structure 1120 can include 2 to 15, such as 5 to10 second strain-modulating layer stacks (1122, 1124), although lesserand greater number of repetitions can also be employed. The totalthickness of the second superlattice structure 1120 can be in a rangefrom 20 nm to 150 nm, although lesser and greater thicknesses can alsobe employed. The second superlattice structure 1120 can include a lowernumber of strain-modulating layer stacks (i.e., a lower number oflayers) than the first superlattice structure 1110.

Each strain-modulating layer stack (1112, 1114) or (1122, 1124) canfunction as buffer layers that provide strain accommodation between twolayers that are located on opposite sides of the strain-modulating layerstack in the respective superlattice structure (1110, 1120). Forexample, the difference in the lattice parameters of the singlecrystalline n-doped gallium nitride layer 804 and the planarlight-emitting indium gallium nitride layer 1132 can be accommodated bythe strain-modulating layer stacks which provide gradual transition oflattice parameters between the single crystalline n-doped galliumnitride layer 804 and the planar light-emitting indium gallium nitridelayer 1132 so that the planar light-emitting indium gallium nitridelayer 1132 can be formed as a high quality epitaxial film. Thesuperlattice structures (1110, 1120) stop lattice defects, such asdislocations and other defects from propagating from the substrate orunderlying layer 804 into the light emitting region 1130 (i.e., activeregion) containing the planar light-emitting indium gallium nitridelayer 1132.

It is noted that the indium gallium nitride and gallium nitride layersin the plurality of strain-modulating layer stacks (1112, 1114) or(1122, 1124) have respective Wurtzite structures. As used herein, an“effective lattice constant” of a layer stack having a Wurtzitestructure is the weighted average of hexagonal-plane lattice constants“a” of the Wurtzite structures of all component layers within the layerstack in which each lattice constant “a” is weighted by the fractiondefined by the number of all atoms within the respective component layerdivided by the number of all atoms within the layer stack.

In one embodiment, the effective lattice parameter and the atomicconcentration of indium in the intervening indium gallium nitride layers(1112, 1122) of the plurality of strain-modulating layer stacks (1112,1114) or (1122, 1124) can monotonically increase with the physicaldistance of each strain-modulating layer stack (1112, 1114) or (1122,1124) from the single crystalline n-doped GaN portion, i.e., from thesingle crystalline n-doped gallium nitride layer 804. Thus, the bottomfirst intervening indium gallium nitride layer 1112 in the firstsuperlattice 1110 may have a lower indium content and a lower latticeparameter than the top first intervening indium gallium nitride layer1112 in the first superlattice 1110. Alternatively, all firstintervening indium gallium nitride layers 1112 in the first superlattice1110 may have about the same indium content and the same latterparameter.

Likewise, in one embodiment, the bottom second intervening indiumgallium nitride layer 1122 in the second superlattice 1120 may have alower indium content and a lower lattice parameter than the top secondintervening indium gallium nitride layer 1122 in the second superlattice1120. Alternatively, all second intervening indium gallium nitridelayers 1122 in the second superlattice 1120 may have about the sameindium content and the same latter parameter.

Optionally, a planar GaN spacer layer 1118 can be provided between thegroups of the first strain-modulating layer stacks (1112, 1114) of thefirst superlattice structure 1110 and the groups of the secondstrain-modulating layer stacks (1122, 1124) of the second superlatticestructure 1120 to reduce overall strain during the epitaxial growth ofthe layers. For example, the planar GaN spacer layer 1118 can have athickness in the range from 30 nm to 50 nm, although lesser and greaterthicknesses can also be employed. The planar GaN spacer layer 1118 maybe not intentionally doped with p-type or n-type dopants. Such GaN layerthat is not intentionally doped typically has n-type conductivity.

The light emitting region 1130 may comprise a planar light-emittingquantum well 1130. The planar light-emitting quantum well 1130 can beformed on the most distal strain-modulating layer stack, which can bethe most distal second strain-modulating layer stack (1122, 1124) withinthe second superlattice structure 1120. The planar light-emittingquantum well 1130 includes a planar light-emitting indium galliumnitride layer 1132, a planar aluminum gallium nitride layer 1133, and aplanar GaN barrier layer 1134, in that order. In one embodiment, theselayers are not intentionally doped.

The planar light-emitting indium gallium nitride layer 1132 includes anepitaxial indium gallium nitride material having a composition thatemits light at a peak wavelength in a range from 600 nm to 750 nm, andpreferably in a range from 610 nm to 680 nm. In one embodiment, theplanar light-emitting indium gallium nitride layer 1132 has acomposition of In_(x)Ga_((1-x))N, in which x is in a range from 0.26 to0.55 (i.e., higher indium content than underlying indium gallium nitridelayers 1112 and 1122). In one embodiment, the planar light-emittingindium gallium nitride layer 1132 can have a thickness in a range from 2nm to 5 nm.

The planar aluminum gallium nitride layer 1133 can have a composition ofAl_(y)Ga_((1-y))N, in which y is in a range from 0.3 to 1.0 (such asfrom 0.5 to 0.8). In one embodiment, the planar aluminum gallium nitridelayer can have a thickness in a range from 0.5 nm to 5.0 nm, such asfrom 0.5 nm to 1.0 nm. Without wishing to be bound by any particulartheory, it is believed that the planar aluminum gallium nitride layer1133 reduces or prevents evaporation of indium from the underlyingplanar light-emitting indium gallium nitride layer 1132 duringdeposition to provide a sufficiently high indium content in layer 1132to permit layer 1132 to emit visible light with a peak wavelength in thered color range (e.g., to emit red light). Additionally oralternatively, modification of band structure and piezoelectric effectsof the second superlattice structure 1120 may enable shift of the peakwavelength from the aluminum gallium nitride layer 1133 toward a longerwavelength, i.e., toward the red wavelength range from 610 nm to 680 nm.Furthermore, the planar aluminum gallium nitride layer 1133 may providestrain compensation with the p-side layers 1140 and 1150 to providebetter quality (i.e., lower defect) p-side layers and/or may moderatethe quantum well band structure in the planar aluminum gallium nitridelayer 1132 due to an undesirable piezoelectric effect which separateselectrons and holes. The strain compensation can occur between thequantum well (that emits the red light) and the rest of the epitaxialstack, principally to reduce misfit defect formation in the active layeritself (as well as in the p-layers).

The planar GaN barrier layer 1134 can have a thickness in a range from15 nm to 20 nm, although lesser and greater thicknesses can also beemployed. The planar GaN barrier layer 1134 provides an energy barrierbetween the planar light-emitting indium gallium nitride layer 1132 andp-type compound semiconductor material layers to be subsequently formed(e.g., to form a quantum well for light emission).

The various material layers within the first superlattice structure1110, the planar GaN spacer layer 1118, the second superlatticestructure 1120, and the planar light-emitting quantum well 1130 can be“undoped,” i.e., be intrinsic (i.e., free of electrical dopants), orhave a low level of dopant concentration that is typically caused byincorporation of residual dopants in a reactor chamber. As used herein,an “undoped” semiconductor material refers to a semiconductor materialthat has not been subjected to an intentional doping process duringfabrication. It is well known in the art that an undoped semiconductormaterial typically has a free charge carrier concentration this isinsufficient to render the semiconductor material conductive. Typically,an undoped semiconductor material has a free charge carrierconcentration not greater than 1.0×10¹⁶/cm³.

A planar p-doped III-nitride layer, such as p-doped aluminum galliumnitride layer 1140 can be formed on the planar light-emitting quantumwell 1130. For example, the planar p-doped aluminum gallium nitridelayer 1140 can be formed directly on the planar GaN barrier layer 1134.In one embodiment, the planar p-doped aluminum gallium nitride layer1140 can have a thickness in a range from 10 nm to 20 nm, althoughlesser and greater thicknesses can also be employed. In one embodiment,the planar p-doped aluminum gallium nitride layer 1140 can be p-doped ata dopant concentration that provides a free charge carrier concentration(i.e., the concentration of holes) in a range from 1.0×10¹⁷/cm³ to3.0×10²⁰/cm³, such as from 3.0×10¹⁷/cm³ to 1.0×10²⁰/cm³, although lesserand greater free charge carrier concentrations can also be employed. Theplanar p-doped aluminum gallium nitride layer 1140 can have a loweraluminum contact than the aluminum gallium nitride layer 1133. Forexample, the planar p-doped aluminum gallium nitride layer 1140 can havea composition Al_(z)Ga_((1-z))N, in which z is less than 0.5, such as ina range from 0.2 to 0.3.

An optional first p-doped compound semiconductor material layer 1150 canbe formed on the planar p-doped aluminum gallium nitride layer 1140. Thefirst p-doped compound semiconductor material layer 1150 can include ap-doped single crystalline compound semiconductor material such asp-doped gallium nitride. In one embodiment, the first p-doped compoundsemiconductor material layer 1150 can be p-doped at a dopantconcentration that provides a free charge carrier concentration (i.e.,the concentration of holes) in a range from 1.0×10¹⁷/cm³ to3.0×10²⁰/cm³, such as from 3.0×10¹⁷/cm³ to 1.0×10²⁰/cm³, although lesserand greater free charge carrier concentrations can also be employed.

A second p-doped compound semiconductor material layer 1160 can beformed on the first p-doped compound semiconductor material layer 1150.The second p-doped compound semiconductor material layer 1160 caninclude a heavily p-doped single crystalline compound semiconductormaterial such as p-doped gallium nitride. The dopant concentration inthe second p-doped compound semiconductor material layer 1160 can begreater than the dopant concentration in the first p-doped compoundsemiconductor material layer 1150. In one embodiment, the second p-dopedcompound semiconductor material layer 1160 can be heavily p-doped at adopant concentration that provides a free charge carrier concentration(i.e., the concentration of holes) in a range from 5.0×10¹⁹/cm³ to3.0×10²¹/cm³, such as from 1.0×10²⁰/cm³ to 2.0×10²¹/cm³, although lesserand greater free charge carrier concentrations can also be employed. Thetotal thickness of the first and second p-doped compound semiconductormaterial layers (1150, 1160) can be in a range from 90 nm to 200 nm,although lesser and greater thicknesses can also be employed.

A transparent conductive electrode, such as a transparent conductiveoxide layer 964 can be deposited over the first and second p-dopedcompound semiconductor material layers (1150, 1160). In case lightemitted from the light-emitting indium gallium nitride layer 1132 isdirected downward toward the single crystalline n-doped gallium nitridelayer 804 by a reflector layer to be subsequently formed above thetransparent conductive electrode, then the transparent conductive oxidelayer 964 is herein referred to a backside transparent conductive oxidelayer 964. The transparent conductive oxide layer 964 includes atransparent conductive oxide material such as indium tin oxide oraluminum doped zinc oxide. The transparent conductive oxide layer 964can be deposited as a continuous material layer that extends across theentire area of the p-doped compound semiconductor material layer 812.The thickness of the transparent conductive oxide layer 964 can be in arange from 100 nm to 2 microns, such as from 200 nm to 1 micron,although lesser and greater thicknesses can also be employed.

Optionally, a reflector material can be deposited to form a reflectorlayer 966 that continuously extends over the backside transparentconductive oxide layer 964. The reflector layer 966 is electricallyshorted to the p-doped compound semiconductor material layer 1160through the backside transparent conductive oxide layer 964. In oneembodiment, the reflector layer 966 includes at least one materialselected from silver, aluminum, copper, and gold. In one embodiment, thereflector material can be deposited by physical vapor deposition(sputtering) or vacuum evaporation. The reflector layer 966 can beemployed to reflect light emitted from the active region 1130 throughthe transparent substrate 802.

Subsequently, additional processing steps of FIG. 36 can be performed toform a dielectric material layer, and the processing steps of FIGS. 37and 38 can be performed to provide a plurality of first light emittingdiodes 10R. Upon singulation into multiple first light emitting diodes10R, each planar material layer of the structure of FIG. 41 becomes alayer that is parallel to a respective portion of the single crystallinen-doped GaN layer within a first light emitting diode 10R, which is asingle crystalline n-doped GaN portion having a planar top surface.

Each first light emitting diode 10R includes a section of the firstexemplary planar material layer stack illustrated in FIG. 41. Each firstlight emitting diode 10R includes a single crystalline n-doped GaNportion that is a single crystalline n-doped GaN layer having a planartop surface. Each layer within the plurality of strain-modulating layerstacks, the light-emitting indium gallium nitride layer, the GaN barrierlayer, and the p-doped aluminum gallium nitride layer are planar layershaving a respective top surface and a respective bottom surface that areparallel to the planar top surface of the single crystalline n-doped GaNlayer.

Referring to FIG. 42, a second exemplary planar material layer stack isillustrated, which can be derived from the first exemplary planarmaterial layer stack by modifying the light emitting region 1130 toinclude two planar light-emitting quantum wells (i.e., to include tworepetitions of a light-emitting indium gallium nitride layer 1132, aplanar aluminum gallium nitride layer 1133, and a GaN barrier layer1134). Thus, the light emitting region 1130 of the second exemplaryplanar material layer stack includes a stack, from a proximal side tothe planar single crystalline n-doped GaN layer 804 to a distal sidefrom the planar single crystalline n-doped GaN layer 804, alight-emitting indium gallium nitride layer 1132, a planar aluminumgallium nitride layer 1133, a GaN barrier layer 1134, an additionallight-emitting indium gallium nitride layer 1132 located on the GaNbarrier layer 1134, an addition planar aluminum gallium nitride layer1133, and an additional GaN barrier layer 1134 located on the additionallight-emitting indium gallium nitride layer 1133. The p-doped aluminumgallium nitride layer 1140 can be formed directly on the additional GaNbarrier layer 1134.

Additional processing steps can be performed on the second exemplaryplanar material layer stack as on the first exemplary planar materiallayer sack of FIG. 41 to provide first light emitting diodes 10R.

If the first or second exemplary planar material layer stack of FIGS. 41and 42 is employed, the first light emitting diodes 10R can be providedby forming a planar layer stack on a substrate 802 such that the planarlayer stack has the same layer sequence as the epitaxial material layerstack to be provided within each first light emitting diode 10R, byforming conductive bonding structures (such as the conductive bondingstructures 433 illustrated in FIG. 37) over the planar layer stack, andby dicing the substrate 802 and the planar layer stack to provide thefirst light emitting diodes 10R.

Referring to FIG. 43, an exemplary device structure for formingnanowire-containing light emitting diodes is illustrated. According toan embodiment of the present disclosure, a nanowires growth method isemployed to provide the nanowire-containing light emitting diodes whichemit red visible light.

As used herein, a “p-plane” means a “pyramid plane,” which is a diagonalplane at the tip of the nanowire (e.g., {1101} planes), a “c-plane”represents a (0001) base plane, and an “m-plane” represents any of the{1010} vertical sidewall planes. Growth rate means layer growth ratealong the direction perpendicular to a growth surface when not otherwisespecified.

The exemplary device structure illustrated in FIG. 43 is an in-processstructure for nanowires-containing light emitting diodes on thesubstrate 802. As used herein, an “in-process” structure refers to astructure that is subsequently modified to make a final structure. Thesubstrate 802 can include a growth substrate 22 (such as a sapphiresubstrate), an optional buffer semiconductor layer 24, and a planarsingle crystalline n-doped GaN layer 26. The planar single crystallinen-doped GaN layer 26 functions as one node of each light emitting diodeto be subsequently formed. The optional buffer semiconductor layer 24and the planar single crystalline n-doped GaN layer 26 can be formed byan epitaxial deposition process so that each of the buffer semiconductorlayer 24 and the planar single crystalline n-doped GaN layer 26 includesa single crystalline semiconductor material that is epitaxially alignedto the single crystalline structure of the growth substrate 802 (whichcan include a single crystalline sapphire (Al₂O₃) substrate).

A growth mask 42 is subsequently formed on the top surface of the planarsingle crystalline n-doped GaN layer 26. The growth mask 42 includes adielectric material such as silicon nitride or silicon oxide, and can beformed, for example, by chemical vapor deposition. The thickness of thegrowth mask 42 can be in a range from 10 nm to 500 nm, although lesserand greater thicknesses can also be employed.

Openings 43 are formed through the growth mask 42, for example, byapplication and patterning of a photoresist layer (not shown) and asubsequent etch process that etches physically exposed portions of thegrowth mask 42 employing the patterned photoresist layer as an etchmask. The photoresist layer can be subsequently removed, for example, byashing. The openings may be circular, elliptical, or polygonal. In anillustrative example, the maximum lateral dimension of each opening 43(such as a diameter or a major axis) may be in a range from 50 nm to 500nm, although lesser and greater maximum lateral dimensions can beemployed for each. The openings 43 can form a two-dimensional array,which may be, for example, a hexagonal array (which includes anequilateral triangular array), a rectangular array, or aparallelogramatic array. The center-to-center distance between aneighboring pair of openings 43 can be in a range from 150 nm to 5microns, although lesser and greater spacings can also be employed.

Referring to FIG. 44, nanowire cores 32 can be grown through theopenings 43 in the patterned growth mask 42 by a selective epitaxyprocess performed in a Group V limited regime. Alternatively, a siliconenriched growth CVD method, a pulsed growth CVD method or an MBE methodcan be employed to form the nanowire cores 32. Each nanowire cores 32extends through a respective opening 43 in the patterned growth mask 42along a direction substantially perpendicular to the top surface of thesubstrate 802. The nanowire cores 32 can be grown from the physicallyexposed surfaces of the planar single crystalline n-doped GaN layer 26by a selective epitaxy process under process conditions that provideepitaxial growth of a single crystalline doped semiconductor materialhaving a doping of the first conductivity type (such as n-doped GaN)along the direction perpendicular to the c-plane. The c-plane can beparallel to the top surface of the planar single crystalline n-doped GaNlayer 26. Growth of the nanowire cores 32 can be performed by aselective semiconductor deposition process that grows a singlecrystalline semiconductor material from physically exposed semiconductorsurfaces primarily along the c-direction, i.e., the directionperpendicular to the c-plane, while not growing any semiconductormaterial from dielectric surfaces. The entirety of each nanowire core 32can be single crystalline and in epitaxial alignment with the planarsingle crystalline n-doped GaN layer 26.

As used herein, the aspect ratio of each nanowire core 32 is defined asthe final height of the nanowire core to the maximum lateral dimensionat the base of the nanowire core, which is the maximum lateral dimensionof the respective opening through the growth mask 42. The aspect ratioof the nanowire cores 32 can be in a range from 2 to 40, although lesserand greater aspect ratios can also be employed.

Referring to FIGS. 45, 46A and 46B, a shell layer stack 34 is formed oneach nanowire cores 32, which is a single crystalline n-doped GaNportion. FIG. 46A is a magnified view of a region M of the exemplarydevice structure of FIG. 45 and FIG. 46B is magnified TEM micrograph ofa region R of the exemplary device structure of FIG. 45. The growth modecan change to a Group III limited growth mode, which is also referred toas a high V/III growth mode employed in conventional growth of III-Vmaterials, for formation of the shell layers within the shell layerstack 34. Thus, the shell layers can be formed on all physically exposedsemiconductor surfaces during the respective selective epitaxyprocesses.

The shell layer stack 34 can include an epitaxial shell layer stack(i.e., a stack of epitaxial shell layers that are epitaxially alignedamong one another) that includes, in order, an optional plurality ofshell strain-modulating layer stacks (1210, 1220, 1225), a shelllight-emitting quantum well that includes a shell light-emitting indiumgallium nitride layer 1232, a shell aluminum gallium nitride layer 1133,a shell GaN barrier layer 1234, and a shell p-doped aluminum galliumnitride layer 1240. The shell light-emitting indium gallium nitridelayer 1232 is configured to emit light at a first peak wavelength in arange from 600 nm to 750 nm under electrical bias thereacross. In oneembodiment, the first peak wavelength can be in a range from 610 nm to680 nm. As used herein, a “shell layer” refers to a continuous materiallayer that laterally encloses and overlies all facets of a nanowire core32. The thickness of a shell layer may vary across facets of thenanowire core 32. For example, vertical portions of a shell layer may bethicker than angled portions of the shell layer.

Each strain-modulating layer stack (1210, 1220, 1225) includes at leasta pair of layers that includes a respective intervening indium galliumnitride layer (1212, 1222, 1226) and a respective intervening GaN layer(1214, 1224, 1228). The inner most strain-modulating layer stack maycomprise a superlattice shell 1210 which contains a plurality of stacksof pairs of layers 1212 and 1214. Each strain-modulating layer stack(1210, 1220, 1225) can function as buffer layers that provide strainrelaxation between two layers that are located on opposite sides of thestrain-modulating layer stack (1210, 1220, 1225). For example, thedifference in the lattice parameters of the single crystalline n-dopedgallium nitride portion of the nanowire cores 32 and the shelllight-emitting indium gallium nitride layer 1232 can be accommodated bythe strain-modulating layer stack (1210, 1220, 1225), which providegradual transition of lattice parameters and trap lattice defectsbetween the nanowire core 32 and the shell light-emitting indium galliumnitride layer 1232 so that the shell light-emitting indium galliumnitride layer 1232 can be formed as a high quality epitaxial film.

The various layers in the plurality of shell strain-modulating layerstacks (1210, 1220, 1225) have respective Wurtzite structures. In anillustrative example, the plurality of strain-modulating layer stacks(1210, 1220, 1225) can include a superlattice shell 1210 of a plurality(e.g., five to ten) of first strain-modulating layer stacks (1212,1214), a second strain-modulating layer stack 1220, and a thirdstrain-modulating layer stack 1225. Each first strain-modulating layerstack (1212, 1214) can include a first intervening indium galliumnitride layer 1212 and a first intervening GaN layer 1214. The secondstrain-modulating layer stack 1220 can include a second interveningindium gallium nitride layer 1222 and a second intervening GaN layer1224. The third strain-modulating layer stack 1225 can include a thirdintervening indium gallium nitride layer 1226 and a third interveningGaN layer 1228.

Each of the first strain-modulating layer stacks (1212, 1214) can have afirst effective lattice constant, the second strain-modulating layerstack 1220 can have a second effective hexagonal-plane lattice constantthat is greater than the first effective hexagonal-plane latticeconstant, and the third strain-modulating layer stack 1225 can have athird effective hexagonal-plane lattice constant that is greater thanthe second effective hexagonal-plane lattice constant.

In one embodiment, the atomic concentration of indium in the interveningindium gallium nitride layers (1212, 1222, 1226) of the plurality ofstrain-modulating layer stacks (1210, 1220, 1225) can monotonicallyincrease with the physical distance of each strain-modulating layerstack (1210, 1220, 1225) from the single crystalline n-doped GaNportion, i.e., from the nanowire core 32.

In one embodiment, the first intervening indium gallium nitride layers1212 can have a lower indium concentration than the second interveningindium gallium nitride layer 1222. For example, the first interveningindium gallium nitride layers 1212 can have a composition ofIn_(p)Ga_((1-p))N in which p is in a range from 0.04 to 0.08, althoughlesser and greater values for p can also be employed. The secondintervening indium gallium nitride layer 1222 can have a composition ofIn_(q)Ga_((1-q))N in which p is in a range from 0.10 to 0.12, althoughlesser and greater values for q can also be employed. The thirdintervening indium gallium nitride layer 1226 can have a composition ofIn_(r)Ga_((1-r))N in which r is in a range from 0.15 to 0.30, althoughlesser and greater values for r can also be employed. The thickness ofeach first intervening indium gallium nitride layer 1212 can be in arange from 0.7 nm to 1.5 nm, although lesser and greater thicknesses canalso be employed. The thickness of each first intervening GaN layer 1214can be in a range from 3 nm to 5 nm, although lesser and greaterthicknesses can also be employed. The thickness of the secondintervening indium gallium nitride layer 1222 can be in a range from 4nm to 6 nm, although lesser and greater thicknesses can also beemployed. The thickness of the second intervening GaN layer 1224 can bein a range from 2 nm to 4 nm, although lesser and greater thicknessescan also be employed. The thickness of the third intervening indiumgallium nitride layer 1226 can be in a range from 2.5 nm to 8 nm,although lesser and greater thicknesses can also be employed. Thethickness of the third intervening GaN layer 1224 can be in a range from6 nm to 10 nm, although lesser and greater thicknesses can also beemployed.

Optionally, a shell GaN spacer layer 1218 can be provided between thegroups of the first strain-modulating layer stacks (1212, 1214) (i.e.,the superlattice shell 1210) and the second strain-modulating layerstack 1220 to reduce overall stress during the epitaxial growth of theshell layers. For example, the shell GaN spacer layer 1218 can have athickness in the range from 30 nm to 50 nm, although lesser and greaterthicknesses can also be employed.

In one embodiment, the effective hexagonal-plane lattice constant of thesecond strain-modulating layer stack 1220 can be greater than theeffective hexagonal-plane lattice constant of the first superlatticeshell 1210, and the effective hexagonal-plane lattice constant of thethird strain-modulating layer stack 1225 can be greater than theeffective hexagonal-plane lattice constant of the secondstrain-modulating layer stack 1220. Further, the atomic concentration ofindium in the second intervening indium gallium nitride layer 1222 canbe greater than the atomic concentration of indium in the firstintervening indium gallium nitride layers 1212, and the atomicconcentration of indium in the third intervening indium gallium nitridelayer 1226 can be greater than the atomic concentration of indium in thesecond intervening indium gallium nitride layer 1222. The atomicpercentage of indium in the second strain-modulating layer stack 1220can be greater than the atomic percentage of indium in the superlatticeshell 1210, and the atomic percentage of indium in the thirdstrain-modulating layer stack 1225 can be greater than the atomicpercentage of indium in the second strain-modulating layer stack 1220.

The superlattice shell 1210 can emit UV radiation, the secondstrain-modulating layer stack 1220 can emit blue visible light and thethird strain-modulating layer stack 1225 can emit green visible light.In one embodiment, the second strain-modulating layer stack 1220 canhave a non-uniform surface profile having at least 3 peaks, where eachof the at least 3 peaks is separated from an adjacent one of the atleast 3 peaks by a valley; and each of the at least 3 peaks extends atleast 2 nm in a radial direction away from an adjacent valley, asdescribed in U.S. Pat. No. 9,281,442, which is incorporated by referenceherein in its entirety. This second strain-modulating layer stack 1220with the non-uniform surface profile can be used for surface profilemodification/preparation of the light emitting region shell 1230 withindium rich regions in addition to strain management.

The light emitting region shell 1230 can be a light-emitting quantumwell which is formed on the most distal strain-modulating layer stack,which can be the third strain-modulating layer stack 1225. The shelllight-emitting quantum well 1230 includes a shell light-emitting indiumgallium nitride layer 1232, a shell aluminum gallium nitride layer 1233,and a shell GaN barrier layer 1234.

The shell light-emitting indium gallium nitride layer 1232 includes anepitaxial indium gallium nitride material having a composition thatemits light at a peak wavelength in a range from 600 nm to 750 nm, andpreferably in a range from 610 nm to 680 nm. In one embodiment, theshell light-emitting indium gallium nitride layer 1232 can have athickness in a range from 3 nm to 7 nm.

In one embodiment, the shell light-emitting indium gallium nitride layer1232 contains indium rich regions having at least 5 atomic percenthigher indium content than indium poor regions in the active regionquantum well shell, which is believed to be at least in part due to thenon-uniform surface profile of the underlying second strain-modulatinglayer stack 1220, as described in U.S. Pat. No. 9,281,442.

In one embodiment, the shell light-emitting indium gallium nitride layer1232 also contains indium rich “nano-ring” or “eave” region 1232A shownin FIG. 46B. The nano-ring region 1232A comprises a structuraldiscontinuity from the p-plane in the upper tip portion of the shell tothe m-plane in the lower portion of the shell, as described in PCTInternational Publication Number WO 2106/025325 A1 and its priority U.S.provisional application Ser. No. 62/036,363 filed Aug. 12, 2014, both ofwhich are incorporated herein by reference in their entirety. Region1232A has at least 5 atomic percent higher indium content than upper tipportion of the layer 1232 having the sloped p-plane sidewalls and thelower portion of the layer 1232 having the substantially verticalm-plane side. The nano-ring region 1232A is a ring shaped region whichsurrounds an entire periphery of a middle portion of the nanowire core32 between the upper tip portion and the lower portion of the nanowirecore 32. The nano-ring region 1232A may contain at least a 3:7 atomicratio of indium to gallium, such as a 3.5:6.5 greater atomic ratio ofindium to gallium. However, other ratios, such as less than 3:7 may alsobe used. In one embodiment, at least a portion (such as at least thenano-ring region 1232A) of the shell light-emitting indium galliumnitride layer 1232 has a composition of In_(x)Ga_((1-x))N, in which x isin a range from 0.26 to 0.55, such as 0.35 to 0.50.

The shell aluminum gallium nitride layer 1233 includes a thin aluminumgallium nitride material that can prevent evaporation of indium from theunderlying shell light-emitting indium gallium nitride layer 1232 duringfabrication. The shell aluminum gallium nitride layer 1233 can have acomposition of Al_(y)Ga_((1-y))N, in which y is in a range from 0.3 to1.0 (such as from 0.5 to 0.8). In one embodiment, the shell aluminumgallium nitride layer can have a thickness in a range from 0.2 nm to 3.0nm (such as 0.5 nm to 1.5 nm), such as from 0.5 nm to 1.0 nm.

The shell GaN barrier layer 1234 can have a thickness in a range from 5nm to 20 nm. The shell GaN barrier layer 1234 provides an energy barrierbetween the shell light-emitting indium gallium nitride layer 1232 andp-type compound semiconductor material layers to be subsequently formed.Optionally, one or more of the various strain-modifying layers (1210,1218, 1220, 1225) described above may be omitted and the shelllight-emitting quantum well 1230 may be formed directly on the nanowirecore 32, on a GaN or AlGaN barrier layer, and/or on one of the othershell layers located on the nanowire core 32, due to the nano-compliancyof the nanowire core 32.

The various material layers within the superlattice shell 1210, theshell GaN spacer layer 1218, the second strain-modulating layer stack1220, the third strain-modulating layer stack 1225, and the shelllight-emitting quantum well 1230 can be undoped (e.g., not intentionallydoped), and may have a free charge carrier concentration not greaterthan 1.0×10¹⁹/cm³.

A shell p-doped aluminum gallium nitride layer 1240 can be formed on theshell layer stack 34, i.e., on the shell light-emitting quantum well1230. For example, the shell p-doped aluminum gallium nitride layer 1240can be formed directly on the shell GaN barrier layer 1234. In oneembodiment, the shell p-doped aluminum gallium nitride layer 1240 canhave a thickness in a range from 10 nm to 30 nm, although lesser andgreater thicknesses can also be employed. In one embodiment, the shellp-doped aluminum gallium nitride layer 1240 can be p-doped at a dopantconcentration that provides a free charge carrier concentration (i.e.,the concentration of holes) in a range from 1.0×10¹⁷/cm³ to3.0×10²⁰/cm³, such as from 3.0×10¹⁷/cm³ to 1.0×10²⁰/cm³, although lesserand greater free charge carrier concentrations can also be employed. Theshell p-doped aluminum gallium nitride layer 1240 can have a loweraluminum content than the shell aluminum gallium nitride layer 1233 andcan have a composition of Al_(z)Ga_((1-z))N, in which z is less than0.5, such as in a range from 0.2 to 0.3.

Referring to FIG. 47, a first p-doped compound semiconductor materiallayer 1250 can be formed on the shell stack 34 (e.g., on the shellp-doped aluminum gallium nitride layer 1240 which forms the outersurface of the shell stack 34). The first p-doped compound semiconductormaterial layer 1250 can include a p-doped single crystalline compoundsemiconductor material such as p-doped gallium nitride. In oneembodiment, the first p-doped compound semiconductor material layer 1250can be p-doped at a dopant concentration that provides a free chargecarrier concentration (i.e., the concentration of holes) in a range from1.0×10¹⁷/cm³ to 3.0×10²⁰/cm³, such as from 3.0×10¹⁷/cm³ to 1.0×10²⁰/cm³,although lesser and greater free charge carrier concentrations can alsobe employed. The deposited p-doped compound semiconductor materialcoalesces between the nanowires, with or without vertical seams or voidslaterally surrounding each nanowire, to form the first p-doped compoundsemiconductor material layer 1250 as a continuous material layer.

Each combination of a nanowires core 32, a shell layer stack 34, a shellp-doped aluminum gallium nitride layer 1240, and a first p-dopedcompound semiconductor material layer 1250 constitutes a semiconductornanowire 1300.

Referring to FIG. 48, a second p-doped compound semiconductor materiallayer 1260 can be formed on the first p-doped compound semiconductormaterial layer 1250. The second p-doped compound semiconductor materiallayer 1260 can include a p-doped single crystalline compoundsemiconductor material such as p-doped gallium nitride. The dopantconcentration in the second p-doped compound semiconductor materiallayer 1260 can be greater than the dopant concentration in the firstp-doped compound semiconductor material layer 1250. In one embodiment,the second p-doped compound semiconductor material layer 1260 can bep-doped at a dopant concentration that provides a free charge carrierconcentration (i.e., the concentration of holes) in a range from5.0×10¹⁹/cm³ to 3.0×10²¹/cm³, such as from 1.0×10²⁰/cm³ to 2.0×10²¹/cm³,although lesser and greater free charge carrier concentrations can alsobe employed. The thickness of the second p-doped compound semiconductormaterial layer 1260 is selected such that the second p-doped compoundsemiconductor material layer 1260 is either formed as a continuousmaterial layer filling the gaps between the semiconductor nanowires 1300and providing a continuous top surface or forms an air-bridge structureenclosing air gaps between the semiconductor nanowires, as described inU.S. Pat. No. 8,350,249, incorporated herein by reference in itsentirety.

Referring to FIG. 49, a transparent conductive electrode, such as atransparent conductive oxide layer 964 can be deposited over the firstand second p-doped compound semiconductor material layers (1250, 1260).In case light emitted from the light-emitting indium gallium nitridelayer 1232 is directed downward toward the single crystalline n-dopedgallium nitride layer 26 by a reflector layer 966 to be subsequentlyformed above the transparent conductive electrode, then the transparentconductive oxide layer 964 is herein referred to a backside transparentconductive oxide layer 964. The transparent conductive oxide layer 964includes a transparent conductive oxide material such as indium tinoxide or aluminum doped zinc oxide. The transparent conductive oxidelayer 964 can be deposited as a continuous material layer that extendsacross the entire area of the first and second p-doped compoundsemiconductor material layers (1250, 1260). The transparent conductiveoxide layer 964 can be discontinuous (for example, by patterning) acrossneighboring groups of light emitting diodes to enable independentoperation of each group of light emitting diodes. The thickness of thetransparent conductive oxide layer 964 can be in a range from 100 nm to2 microns, such as from 200 nm to 1 micron, although lesser and greaterthicknesses can also be employed.

Optionally, a reflector material can be deposited to form a reflectorlayer 966 that continuously extends over the backside transparentconductive oxide layer 964. The reflector layer 966 is electricallyshorted to the first and second p-doped compound semiconductor materiallayers (1250, 1260) through the backside transparent conductive oxidelayer 964. In one embodiment, the reflector layer 966 includes at leastone material selected from silver, aluminum, copper, and gold. In oneembodiment, the reflector material can be deposited by a directiondeposition method such as physical vapor deposition (sputtering) orvacuum evaporation. The reflector layer 966 can be employed to reflectlight emitted from the light emitting region 1230 downward.

Subsequently, additional processing steps of FIG. 36 can be performed toform a dielectric material layer, and the processing steps of FIGS. 37and 38 can be performed to provide a plurality of first light emittingdiodes 10R. Upon singulation into multiple first light emitting diodes10R, each first light emitting diode can include a plurality ofsemiconductor nanowires 1300.

Each first light emitting diode 10R includes a nanowire core 32 as asingle crystalline n-doped GaN portion, which protrudes vertically froma horizontal surface of a single crystalline n-doped GaN layer 26 havinga planar top surface. An optional shell layer stack 34 comprising eachlayer within the plurality of strain-modulating layer stacks (1210,1220, 1225), the light-emitting indium gallium nitride layer 1232, theGaN barrier layer 1234, and the p-doped aluminum gallium nitride layer1240 laterally surrounds the nanowires core 32 and includes verticalportions that extend along a vertical direction and perpendicular to theplanar top surface of the single crystalline n-doped GaN layer 26.

In the embodiment illustrated in FIGS. 43-49, a planar singlecrystalline n-doped GaN layer 26 having a planar top surface is formedon a substrate 802. Nanowire cores 32 comprising n-doped GaN can beformed on the planar single crystalline n-doped GaN layer 26. A shelllayer stack 34 is formed on the nanowire cores 32. The shell layer stackincludes one or more of shell strain-modulating layer stacks (1210,1220, 1225), a shell light-emitting indium gallium nitride layer 1332, ashell GaN barrier layer 1332, and a shell p-doped aluminum galliumnitride layer 1240. The thicknesses of the layers within shellstrain-modulating layer stacks (1210, 1220, 1225) can be thin toaccommodate the strain on the shell light-emitting indium galliumnitride layer 1332. Alternatively, one or more of the stacks (1210, 1220and/or 1225) can be omitted due to the nano-compliance of the nanowirecore 32 which accommodates the strain on the shell light-emitting indiumgallium nitride layer 133. Conductive bonding structures 433 describedin the prior embodiment are electrically shorted to first and secondp-doped compound semiconductor material layers (1250, 1260) can formed.The substrate 802 and material structures thereupon can be diced toprovide the first light emitting diodes 10R. Portions of the substrate802 can be removed to enable formation of electrical contact to a singlecrystalline n-doped GaN layer (which is a remaining portion of theplanar single crystalline n-doped GaN layer 26) within each first lightemitting diode.

The first light emitting diodes 10R can be bonded to a backplaneemploying any of the methods described above to form an array of pixelsfor a direct view display device. Second light emitting diodes 10Gconfigured to emit light at a second peak wavelength in a range from 400nm to 600 nm can be bonded to the backplane. Optionally, additionallight emitting diodes such as third light emitting diodes 10B can betransferred to the backplane. For example, the second light emittingdiodes may be green-light emitting diodes and the second peak wavelengthcan be in a range from 495 nm to 570 nm, and third light emitting diodes10B may be blue-light emitting diodes configured to emit light at athird peak wavelength in a range from 400 to 495 nm.

In a non-limiting example, each of the first light emitting diodes 10Rcan comprise a first conductive bonding structure 433 that iselectrically connected to a respective p-doped aluminum gallium nitridelayer (1140, 1240) and is bonded to a respective bonding pad 423 on thebackplane 401, and each of the second light emitting diodes 10G cancomprise a second conductive bonding structure 422 that is electricallyshorted to a respective p-doped compound semiconductor material layerwithin the second light emitting diode 10G and is bonded to anotherrespective bonding pad 422 on the backplane 401 as illustrated in FIG.40B.

In one embodiment, each of the first light emitting diodes 10R cancomprise a first reflector layer 966 that is located between therespective p-doped aluminum gallium nitride layer (1140, 1240) and thefirst conductive bonding structure 433 and configured to reflect lighttoward the p-doped aluminum gallium nitride layer (1140, 1240). In oneembodiment, each of the first light emitting diodes 10R can comprise afirst transparent conductive oxide layer 964 that is located between,and electrically shorted to, the p-doped aluminum gallium nitride layer(1140, 1240) and the first conductive bonding structure 433.

In one embodiment, the methods of FIGS. 40A and 40B can be performedafter bonding the light emitting diodes (10R, 10G, 10B) to form an arrayof pixels. Specifically, a dielectric fill material layer 798 laterallysurrounding each of the first light emitting diodes 10R and the secondlight emitting diodes 10G within the array of pixels can be formed afterbonding the first light emitting diodes 10R and the second lightemitting diodes 10G to the backplane 401 as illustrated in FIG. 40A.Subsequently, a front side transparent conductive oxide layer 796 can beformed over the dielectric fill material layer 798 such that the frontside transparent conductive oxide layer 796 is electrically shorted toeach single crystalline n-doped GaN portion (804, 32) in the first lightemitting diodes 10R within the array of pixels. The front sidetransparent conductive oxide layer 796 can be a common ground electrodefor each of the first light emitting diodes 10R and the second lightemitting diodes 10G.

While the red light emitting diodes 10R of the embodiments of FIGS. 41to 49 are described above as being used in a multi-color direct viewdisplay, it should be understood that these red light emitting diodescan be used in any suitable light emitting device where red lightemission is desired, such as a backlight for a LCD display, in alighting fixture (e.g., lamp), a vehicle headlamp, a vehicle tail light,a traffic light, an in-eye projection device, etc.

FIG. 50 is graph showing external quantum efficiency of sample lightemitting devices employing the first exemplary planar material layerstack of FIG. 41 and the second exemplary planar material layer stack ofFIG. 42. The relationship between the peak wavelength and the externalquantum efficiency at 1.2 A/cm² current density is plotted in the graph.Closed circles correspond to data points for samples having theconfiguration of the first exemplary planar material layer stack of FIG.41, and are fitted with a first fitting curve 5001. Open circlescorrespond to data points for samples having the configuration of thesecond exemplary planar material layer stack of FIG. 42, and are fittedwith a second fitting curve 5002. External quantum efficiency greaterthan 2%, such as 2 to 10% for peak emission wavelengths between 600 and640 nm are provided. External quantum efficiency greater than 2% at apeak wavelength greater than 620 and providing crisp red color has beendemonstrated by samples implementing the structures of the presentdisclosure. It is well known that external quantum efficiency in lightemitting diodes rapidly decreases within increase in wavelength above600 nm. External quantum efficiency greater than 2% at a peak wavelengthgreater than 620 nm (such as 3.9% at 628 nm) as provided by samplesimplementing the structures of the present disclosure is believed to besuperior in performance to any known prior art InGaN based red lightemitting devices.

The layer stacks tested were not diced or encapsulated and did not havea reflector. Furthermore, instead of actual electrodes, nickel dots weredeposited on the stacks and subjected to a high voltage spike to diffusethe nickel dots into the stack. The voltage was then measured betweenp-side and n-side dots. A fully encapsulated chip in a silver reflectorheader and with epoxy (a lamp) is expected to deliver a four timesimprovement in EQE relative to nickel dot devices. It should be notedthat the stack with one quantum well in the light emitting regionexhibits a higher external quantum efficiency for a given peak emissionwavelength than a stack with two quantum wells in the light emittingregion. Without wishing to be bound by a particular theory, it isbelieved that this effect may be due to lower strain in the singlequantum well device. Thus, in an embodiment of the present disclosure,the light emitting region contains one or two quantum wells, or three ormore quantum wells.

FIG. 51 is a plot of emission intensity versus wavelength for the secondexemplary planar material stack of FIG. 42. The stack exhibited a fullwidth half maximum (FWHM) of less than 50 nm (e.g., about 45 nm) at acurrent density of 1.2 A/cm².

FIG. 52 shows a current—voltage plot of an unencapsulated, undiced 20micron micro-LED employing the second exemplary planar material stack ofFIG. 42 at 610 nm peak emission wavelength for various operating currentdensity conditions according to an embodiment of the present disclosure.

Referring to FIG. 53, spectral distribution of sample light emittingdevices employing the exemplary device structure of FIG. 49 isillustrated. The peak external quantum efficiency occurs at low currentdensities below 1 A/cm², which makes the nanowire based LED suitable fordirect view displays which operate at below low current densities below1 A/cm².

As described above, the planar and nanowire LEDs of the embodiments ofFIGS. 41-53 exhibit red light emission (e.g., 610 to 650 nm, such as 615to 630 nm) with high external quantum efficiency (e.g., 2 to 10%) forrelatively low current densities (e.g., 1 to 2 A/cm²) and FWHF of 100 nmor less, such as 50 nm or less, for example 45 to 50 nm. The Group IIIcomposition of the aluminum gallium nitride layer (e.g., cap layer)(1133, 1233) in the light emitting region (1130, 1230) may contain lessthan 99% aluminum (e.g., 50 to 80% Al). The devices may contain lessthan five quantum wells (e.g., one or two quantum wells) in the lightemitting region. The devices may also include a superlattice (1110 and1210) UV emitting InGaN/GaN stack and least one blue or green emittingInGaN/GaN stack between the light emitting region and the n-type side ofthe device for strain relief and improvement of light emitting regionquality.

The red light emitting diode of the present disclosure can be a microred LED having a lateral dimension (as measured left to right for thered light emitting diode 10R in FIG. 40B) in a range from 1 micron to100 microns. Multiple red light emitting diodes or a single red lightemitting diode may constitute a single sub-pixel of a display device.For example, an in in-eye projection device can include a single redlight emitting nanowire 1300 as a single red sub-pixel. The red lightdisplay diode of the present disclosure may be employed in a monocolordisplay device formed on a backplane, or in an RGB monolithic displaydevice.

Although the foregoing refers to particular preferred embodiments, itwill be understood that the invention is not so limited. It will occurto those of ordinary skill in the art that various modifications may bemade to the disclosed embodiments and that such modifications areintended to be within the scope of the invention. Where an embodimentemploying a particular structure and/or configuration is illustrated inthe present disclosure, it is understood that the present invention maybe practiced with any other compatible structures and/or configurationsthat are functionally equivalent provided that such substitutions arenot explicitly forbidden or otherwise known to be impossible to one ofordinary skill in the art.

What is claimed is:
 1. A light emitting diode, comprising: an n-dopedportion; a p-doped portion; and a light emitting region located betweenthe n-doped portion and a p-doped portion, the light emitting regioncomprising a light-emitting indium gallium nitride layer emitting lightat a peak wavelength between 610 and 650 nm under electrical biasthereacross; wherein: the light emitting diode comprises a micro-lightemitting diode having a lateral dimension of 100 microns or less; andthe light emitting diode emits the light at the peak wavelength between610 and 650 nm under electrical bias thereacross having an externalquantum efficiency of at least 2%.
 2. The light emitting diode of claim1, wherein the light emitting region further comprises: a III-nitridelayer located on the light-emitting indium gallium nitride layer; and aGaN barrier layer located on the III-nitride layer.
 3. The lightemitting diode of claim 1, wherein the light emitting diode emits thelight at the peak wavelength between 610 and 650 nm under electricalbias thereacross having the external quantum efficiency of 2% to 10%. 4.The light emitting diode of claim 1, wherein the light emitting diodeemits the light at the peak wavelength between 610 and 650 nm underelectrical bias thereacross having the full width half maximum of 100 nmor less.
 5. The light emitting diode of claim 1, wherein the lightemitting diode comprises a red-light emitting diode which is located ina display device.
 6. The display device claim 5, further comprising abackplane.
 7. The display device claim 6, wherein the red-light emittingdiode is located on the backplane.
 8. The display device claim 7,further comprising a green-light emitting light emitting diode locatedon the backplane, and a blue-light emitting diode located on thebackplane.
 9. The display device claim 5, wherein the display devicecomprises an in-eye projection device comprising the light emittingdiode as a single red sub-pixel.
 10. The display device claim 5, whereinthe display device comprises a monocolor display device.
 11. The displaydevice claim 5, wherein the display device comprises a RGB monolithicdisplay device.
 12. A direct view display device, comprising: an arrayof pixels located on a backplane, wherein each of the pixels of thedirect view display device comprises a red-light emitting diodecomprising: an n-doped portion; a p-doped portion; and a light emittingregion located between the n-doped portion and a p-doped portion, thelight emitting region comprising a light-emitting indium gallium nitridelayer emitting light at a peak wavelength between 610 and 650 nm underelectrical bias thereacross, wherein the red-light emitting diodecomprises a micro-light emitting diode having a lateral dimension of 100microns or less.
 13. The direct view display device claim 12, furthercomprising a green-light emitting light emitting diode located on thebackplane, and a blue-light emitting diode located on the backplane. 14.The direct view display device claim 13, wherein the display devicecomprises a RGB monolithic display device.
 15. The direct view displaydevice claim 12, wherein the direct view display device comprises anin-eye projection device comprising the red-light emitting diode as asingle red sub-pixel.
 16. The direct view display device claim 12,wherein the direct view display device comprises a monocolor displaydevice.
 17. The direct view display device claim 12, wherein thered-light emitting diode emits the light at the peak wavelength between610 and 650 nm under electrical bias thereacross having an externalquantum efficiency of at least 2%.
 18. The direct view display deviceclaim 12, wherein the light emitting region further comprises: aIII-nitride layer located on the light-emitting indium gallium nitridelayer; and a GaN barrier layer located on the III-nitride layer.
 19. Thedirect view display device claim 12, wherein the red-light emittingdiode emits the light at the peak wavelength between 610 and 650 nmunder electrical bias thereacross having the external quantum efficiencyof 2% to 10%.
 20. The direct view display device claim 12, wherein thered-light emitting diode emits the light at the peak wavelength between610 and 650 nm under electrical bias thereacross having the full widthhalf maximum of 100 nm or less.